I have an 05 2500HD crewcab 4x4 dmax/ally. 7000 miles, bought it back in march. I've noticed that now when i open up the drivers door, i hear 2 large pops, its very annoying and sounds as if something was broken. So I took it to the dealer where I purchased. They ordered a new door check and said that was the problem. I was there yesterday for over 3 hours and they were installing the new door check. All the other doors are silent when opening and closing. I got the truck back and it still does it. The service guy told me they installed it several times and it didn't seem to fix the problem. They also got white lithium grease all over the door and interior, so I was pissed. They cleaned everything and then I noticed that the door panel was nicked and damaged since they over tightened the mounting screw. So as they ordered another door check, I will also get a new panel too. What could be this problem? Its embarasing that when I open/close the door your hear this noise from a brand new truck. Any ideas?

Hopefully this is your problem. http://dieselplace.com/forum/showthread.php?t=21402&highlight=door+popping

no kidding, go figure the vin has the "F" in it, well, it has to go back to the dealer for the door panel they messed up and if its not fixed, i will take care of it myself. thanks alot!

Why not print out the above thread and give it to the service writer.

...Just looked at mine, "F" in the vin and it was assembled April 8th 2005... I guess it's just a matter of time now.

i figured i'd print it out and see what they say, the fact the customer knows more about these trucks than the service dept is kinda wrong...imo