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Been chasing this for weeks to no avail. Recently layered EPDM foam sheets on the speaker shroud on where that window railing object would likely contact - worked when the door card was off but would come back once I reinstalled the cards.
The clunking sounds extremely loose, as if a rubber ball was suspended in the door cards via a string.
Drove the car with the door card removed - sound is still there.
Driven with the card removed and speaker removed - no sound.
In a few days I'll drive around with the door card attached and with the door switch / speakers removed to see if I could pinpoint the noise down to anything.
What's even more surprising is that I've torn down the dashboard and door countless times trying to isolate the problem yet I still have the patience...
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