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Dealer called. Got my car back. They strongly believe it to be a manufacturing defect in the visor in whatever it was coated with even before it was installed in the car; once exposed to the elements, it deteriorated. So not even the original theory of the plastic wrap causing the issue.
I have to go back when the passenger visor arrives. For some reasons it's weeks back ordered.
They did replace my right front strut and strut mount and the popping noise is now gone.
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