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Cracked sheet metal around the hinge area? - inspect carefully. The metal flexes past the crack and pops when loaded by door weight or the door hinge spring.
I narrowed it down. What's cracking/popping is this black/plastic arm in the middle of the door. The round part that attaches to the frame of the door moves slightly when the door opens/closes and that piece 'cracks'.
The passenger door piece does not move at all, and it does not crack so I suppose the drivers side should not be moving at all.
Anyone know what this piece is called and how to fix this? By the way, its covered with grease in the photo, I was trying to see if the pop would go away.
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