Just bought a new 05 4 runner and have been impressed with the ride. I have had a rattle on the passenger door which goes away after the car has been warmed up. It has been at the dealer for a total of 6 times. Each time they think it is fixed, it reappears. I know they don't think I am crazy becasue they can recreate it. It is frustrating to hear this noise on a new car. To me, it sounds like the mechanism is hitting the door panel and expands when it is warm. They switched out a plastic bushing with another non-plastic bushing.

Any help or ideas would be appreciated

 

that is really odd...i dont understand how the heat would affect it...i cant imagine what it could be...