I'm dealing with the same problem: driver's door popping noises. Dealer said it's a broken weld, the whole door has to be replaced at the cost of close to $2000, it will take 3-4 days, no loaner provided, everything at my own costs. I've sprained my leg, trying to get in and out. I've dealt with Toyota corporate and dealership - no assistance. TOTAL RIP-OFF!!! 2004 Sienna with only 55,000 miles. Recommendation: Call Office of Defects Investigation, NHTSA, 1-888-327-4236 and report this safety problem. THE MORE REPORTS THEY GET, THE BETTER CHANCES THEY'LL GET TOYOTA TO ISSUE A RECALL!!! Check out www.nhtsa.gov, www.safercar.gov We should get media attention to this problem, obviously it's a manufacturing defect, as someone said, it's a matter of WHEN the weld will break, not IF it will break.