So since new I've noticed that there is not enough gap between the dash and the door on the passenger side of my car. In the dead cold of winter, it's fine as long as the interior is cold...there's enough gap. When the interior warms up in the winter, or anytime warm in the summer, the gap closes due to the plastic expanding and the two surfaces between the door and the dash touch, causing an annoying rubbing/popping sound over bumps. My solution at the time was to add some felt to the dash side which alleviated the problem as stated before as the door moving on the felt on the dash does not create any noise. Now either my glovebox is the main culprit (hard to tell at this point), or the fact the door and dash are always in contact (especially with the felt between) it may be causing extra "push" stress to the dash and door which is causing yet another noise (more of a cracking noise this time).

Is there ANY way to increase the amount of gap between the dash and the door? The driver's side is perfect and I know that not all Cobalts are like this because I had a rental which did not have this problem.

If anyone can help with this, thanks! :)