After a windy ride on the highway I discovered that my passenger front door does not lay on the upper rubber seal properly, making it noisier than it needs to be when there is a crosswind.
I have tried everything to solve it. Adjust the door striker every which way, the door hinges themselves by replacing the centering bolts with standard fasteners. Of course I can change the alignment of the door with these methods but nothing corrected this gap. As of now I put the centering bolts back in the hinges to return it to where it was and set the striker in towards the center of the vehicle as much as possible.
I measured the gaps around every other part of the door and they are as expected. Other than this one area.
I have a 2nd 4runner so I can swap the doors and see how it fits. But before I go through that trouble I figured I would see if anyone has any other ideas.
My best guess is that the door frame itself is bent outwards at the top. It is the original door, no idea how this would happen. But you can see from the pics that the back edge is pretty flush with the rear door. If I push the door in (simulating it closing further), the gap shrinks but does not go away. If I push on the upper frame of the door only I can get it to pretty much close the gap.
You can also see that the gap along the a-pillar looks good too. This has clearly been eating away at my soul.
edit: Also I took the seal off and it is in great shape.
Looking at the door from over the hood
From the rear
A-pillar
Door gaps
Top-down showing flushness between front/rear doors.
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2000 SR5 3.4, Manual, 4x4
Icon 2.5 extended coilovers & 2.0 rear, JBA UCAs
265/75R16 General Grabber X3 on LC80s
Full Skid Plates