Actually, to make things a little more clear, here's all the hardware that came with our door (except the hinges, which are already attached).

{{!gwi}}

This is the peg that apparently is supposed to be the guide at the top of the door (we have two of these, one to go on the stationary side, one to go on the moving side).
{{!gwi}}

I have never seen one without the roller for the moving side. All the hardware you have is the same as I have installed countless times minus the roller.

I dont know, maybe you should try a different brand, or take the roller off the old door and use it

The roller version is for a wider track that it's usually paired with, so a roller won't work with that track you have.

That plastic pin version will work just as well, provided the track is installed level. It'll rattle about the same, side to side, as the roller version in it's track.

Yeah, it's really weird, I've never seen them without a roller either. But that's all I can find in the local stores, of any brand. I can buy separate rollers, but the track that came with our door is too narrow for any roller I can find (and the existing track really needs to be replaced), and I haven't seen any separate tracks for sale.

Johnson Hardware has some ok looking ones on their website, so I may end up having to order one online. I was hoping to not have to wait so long (and pay for shipping), but I'd rather have something good than something quick...

Sorry, homebound posted while I was typing my reply.

Are there no versions that won't rattle at all? It seems like it should be possible with a well-designed roller system. The current one just feels so cheap and flimsy when you open the door.

The roller type has to have some rattle or there would be too much friction on the wheel (it needs clearance on one side of the wheel).

Also, since the doors are only supported on one side (and are very light) that flimsy feel is going to be there, for the most part.

Best advice is to make sure everything is level and plumb (including making sure the floor bracket is plumb front to back). It sometimes helps to put a pair of knobs or handles on the door instead of just the one provided.

Alternatively, maybe you would prefer a pair of opposing doors, such as separating those bifolds and installing each on it's own set of hinges? It's been done before. Not too difficult if both sides are plumb. If you have drywall on the sides, then first install a jamb set on both sides and top, then install doors (Stanley had some surface mount hinges that will do the trick), then door stops around (or at least at the top), and finally ball catches at the top.

No more rattle!

Johnson makes about the bast stuff around.

Here is a link that might be useful: Johnson Hardware

Below is a set sold by Lowes. Have you gone to the 'special order' deck at the big box stores and asked about ordering what you want? Or just order it online and if it doesn't work take it back to Lowes!

Here is a link that might be useful: hardware

Listen to Brickeyee, Johnson hardware has the best bifold and bypass door hardware on the market. I have used the bifold hardware in the past on doors in a house we owned and i just purchases new bypass door hardware as i am in the process of replacing a bunch of bypass doors in the house we own now. The stuff is like night and day with the crappy hardware that I am replacing. Johnson hardware isn't the cheapest to buy but it is the highest quality i have found. Plus it is all made in the U.S.

It sounds like you were pounding directly on a spring-loaded pin to set it into a hole on the top of a bifold door. The best way to set these is to force the mechanism into the hole as far as you can by hand, and then, if necessary, use a punch and light taps of a hammer on the rim to set it fully in place. Maybe your hole was a little too tight, but, in any case, pounding directly on the pin is a good way to damage it as you have found out. Unfortunately, I can't suggest another manufacturer, as Johnson is typically the best I've found. However, if you don't want to use them, go to Amazon, do a search, and see who gets the best reviews.