Wind related chirping noise at 70-75mph, getting desperate

I have a 2015 Tacoma and I’m about at my wits end trying to fix this extremely annoying wind related “chirping” noise coming from my front driver door area when driving about 70-75mph. I know there’s issues with our door seals and I’ve seen some videos on applying an extra surrounding layer of D rubber weather stripping. I’m also aware of the TSB about the door seals, both of which I’ve done. I’m wondering if there’s actually just some loose screw or similar thats located outside of where the cabin is that wind is causing to move and subsequently “chirp”. It’s very hard though to tell if it’s just a super high pitched whistle or actual metal on metal moving slightly. However it fully goes away when the window is rolled down so I’m thinking it has to be a leak/gap in a seal somewhere. I just cannot figure out where. Going on a big trip next week with 1500 Highway miles and I’d be elated to fix this before it. Here’s my symptoms and what I’ve tried.


Symptoms:

• Only occurs at 70-75mph with certain wind conditions. Example, I have cruise control set at 75 and as soon as the freeway turns directions it will start
• Noise sounds like a high pitched chirping/fast fluttering that increases/decreases slightly in speed with the wind speed. It almost sounds like some metal screw chirping and the wind is hitting it and causing the noise but it’s super hard to tell, but I think it’s just wind through a tiny gap
• If I barely crack the window the noise remains but as soon as I open it fully it ceases. Then as soon as I roll it all the way up it starts instantly. Definitely seems related to the cabin pressure

What I’ve tried

• TSB replacement with the “upgraded” door seals that contain the extra little rubber tubing
• Replaced window channel runs with new OEM ones
• Removed side view mirror and replaced foam gasket with new thicker foam
• Double additional layers of D and foam weather strip along A pillar and front of door
• For testing, I’ve tried covering the all seam gaps on exterior along a pillar, front of door, and side of windshield with painters tape (no effect)
• For testing I’ve also tried driving with inner door card removed and shuffling a duster in the seams to see if I could make a difference in sound and nothing.
• I’ve also tried shutting the door with a microfiber towel stuck between the door right below/around the A pillar and no difference.

Note:

• I do have window weather guards but the sound is coming from lower down, somewhere just below the tweeter location.
• Could be unrelated, but when hitting big bumps I feel like I heard the same chirp sound momentarily which makes me wonder if something is just loose and the wind is hitting it at high speeds causing the noise. Has anyone had something similar happen?

Area where chirping seems to be coming from:


TSB door seal/weatherstrip, extra D tubing and Foam weather stripping for testing:

 

Check those flimsy "cloth" liner/covers above the strut tower. They cover the gap between the frame rails and the inner fender apron. The little plastic rivets on mine were half broken and a loose end of the liner was slapping against the frame. Only happened at freeway speeds with some wind blowing around under there

 

Thanks for the suggestion. Are you referring to the thin rubber splash guards in the front wheel well? Or something different?

 

Yes. On mine one end of the guard loose and flapping around but it still had a plastic rivet stuck in it. The plastic rivet was tapping against the frame. Crazy how that little piece of plastic could make so much noise in the cabin

 

Sadly that’s not it for me. I replaced those a while back. I just went and shook the flaps by hand and no noise to be had unfortunately. I’m truly at a loss.

 

Are the mudflaps tight?

 

No mudflaps, I removed them. It definitely sounds like wind entering some tight gap, it’s a high pitched chirping/fluttering noise that changes speed with the wind. But I of course could be wrong

 

I think I know the exact sound your talking about, I get it with my 2013. There's one specific stretch of highway it happens on, same speed range you're talking about and that stretch of highway is always incredibly windy. I've always thought it was the driver's side rear view mirror.

 

Definitely could be the same noise, mine only happens on certain highways as well in certain directions related to wind. I suspected the side view mirror as well because if there’s not a good seal of if it’s not fully tight there’s 4 holes directly behind the sail panel that could certainly allow the noise. However I’ve tried the following to no avail:

1. Removed mirror and replaced inner foam gasket with thicker foam
2. Test drove with painters tape applied around the entire side view mirror perimeter where it meets the truck body

The only test I haven’t done is drove with the mirror completely removed and the holes covered with tape but I’d rather not have to do this… though I might now.

Test driving again tonight it does seem to be a leak as it definitely goes away when the window is open enough. I wasn’t sure before but as soon as I roll up the window it gets louder.