Quote:
Originally Posted by Canadian_Yoda
Jumbo, I've got the creaking/popping dash as well... I just want to clarify a few things:
1. My passenger side dash doesn't quite line up at the bottom front corner of the A-pillar. The dash (black) is about 1cm lower than where it looks like it needs to be on the A-pillar (white). Is this the same situation you had? Did this actually line up perfectly after you did your fix?
2. Thanks for the photos, they help a lot. I tried to reach up there the other day to see if I could feel what you were describing, but all I found was something that was REALLY farking hot... Most likely the heater core inlet pipe. I'll try again when I have a bit more time (and when the truck is cold). My question is: how big is the gap you have to fill? or, how much material will I need to stuff in there?
3. From what you have said, I understand that the rattle fix also has the side benefit of the dash alignment fix. I want to make sure that this isn't done in two different fixes, so I don't have to contort myself under my dash more than once.
Thanks again for the excellent info! 
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Yeah, mine didnt line up on the pass. side either. I had the clicking noise on that side where the dash didnt sit tight in the clip. Mine only made the clicking noise on cold mornings. I just stuffed a tight wad of felt up under the clip to create a tight fit and the clicking noise quit and hasnt returned. The dealer is doing the same thing with their "Toyota sound dampening". That fix took about a minute and I didnt have to waste a trip to the dealer.
The air duct rattle behind the radio is about a 1" space that needs to be filled to force the two ducts tightly together. Again, about a minute fix.
Mark