<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by rodster:

I'm not sure the problem is plastic on metal. Might be, might not be.
</div></BLOCKQUOTE>

The reason I think it's plastic on metal is that on my prior '05 SUT there were several spots just under the door panel edge where the paint was scratched off.

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by rodster:

That said, personally, I'd be reluctant to start caulking, taping or otherwise sticking together parts that you may want to disassemble some day.
</div></BLOCKQUOTE>

When I mentioned caulk earlier, I wasn't really thinking of sticking the door panels to the door. What I had in mind was laying a bead of caulk or some other rubber material to cushion the edges. I would let it dry for a while before reinstalling the panels.

<BLOCKQUOTE class="ip-ubbcode-quote"><div class="ip-ubbcode-quote-title">quote:</div><div class="ip-ubbcode-quote-content">Originally posted by rodster:

If your door didn't squeak when new, it stands to reason something is now loose and it seems feasible that what's now loose can be made snug again without adding caulk, etc. </div></BLOCKQUOTE>

My previous '05 SUT squeaked from day one. My current '05 SUV seems much tighter, but I can still detect some of the same noises -- just not as bad.

I think there were some redesigned fasteners put into production during the '05 year, but I'm not sure if my truck has them.