So I've taken my Balt into the dealer 4 times now to try and get rid of a noise, which they've ALMOST fixed, but about 3/4 of the way home, it's back. It's not in full force now, but it's still there. The noise I have is coming from where the passenger door meets the dash when closed. I believe the two are rubbing together over bumps which causes a noise. They adjusted the door this time around which made it better, but still didn't fix it. I'm not in the mood to bring it back a fifth time, so I'd much rather just take care of it myself.

One option I thought of was to use a heat gun to warm the door plastic and try to press it back JUST enough to have it not touch the dash, but I'm afraid it'll look bad.

Another option I thought of was to jam some type of material between the door and dash to see if that muffles it, and if so, cut some out and place it on the dash side (something the same color as the dash). It'll be a little noticeable but could shut it up.

Any other ideas how to add more gap to that area or shut it up? Like I said, I've had it at the dealership four times now and they can't get it right, so I'm going to take matters into my own hands. And no, this is not something that can easily be ignored over the radio, you can often hear it over it unless you're at 3/4 volume or higher.

 

Find the root of the problem first and then come up with a permanent solution.
Dont start taking a heat gun to your trim ,theres got to be a better solution.

 

I found the root of my problem today, it's just where the door and the dash meet, just at the uppermost part of the dash. When the plastic expands (warm weather), the door will touch the dash...I used a piece of paper like a gauge and it would slide between the door and dash when cold, but when the interior warms up, you can't even fit a single piece of paper between the two. I grabbed some felt and put it in the door and closed it to see if this would alleviate the problem, and yes, it is the movement of the two plastics that cause the noise, so when something is put in between, the noise is gone. I trimmed the felt to fit that area (temporarily) and used a glue gun to attach it, that way the glue can be scraped off later when I find a better solution. I guess the dealership just needs to adjust the door when it's warm. I called them to ask if they did that, and they said yes, but apparently they lied, or they just aren't that bright.

So long story short, there's some felt there for now, it's actually not even noticeable because it's the same color as the dash, you have to actually look to see it. I don't think I'll keep it there, but for the time being it's a great alternative.

On the note of the heat gun, I made mention of it because I thought it could be possible to heat up that area of the door enough that you could put some felt or fabric between the door and dash and close it, hence reforming the door so when it's closed there would be more space between the door and dash. That was just a thought.

 

Im thinking that would be a dash adjustment,it might of come off the pins that hold it up and is sagging slightly.
Try pulling up on the dash in that end to see if it can be lifted slightly to alleviate the problem.
A door adjustment I cannot see helping it in anyway.