Re: Popping in front driver door when it opens and closes
I did the fix on my 04 Sienna XLE, 250,000 miles (following the advice of smokey69 in post #73 of thread TSB: NV003-07 DOOR Check Popping NOISE) using a STEEL pop rivet. I purchased an Assortment pop rivet pack from Lowes which contained 1/8" (with 1/4" grip) steel pop rivets. I did not take the door panel off.
While holding the door open and putting slight pressure on the door, I drilled two 1/8" holes using a Dewalt impact drill (because it is shorter than my regular drill to get between the door and door jamb). Had to drill the hole at a slight upward angle because there is not enough room to hold the drill level. The first hole I drilled directly into the spot weld location and the other just to the left of the spot weld. Inserted the two 1/8" steel pop rivets (1/4 inch grip). Done! No more pop noise. I would have preferred to use the larger 3/16" pop rivets as smokey69 suggested but they were not sold at Lowes.
Last edited by Dawedler; 01-09-2017 at 09:08 AM.