I had an issue with wind noise. Dealer could not find it. I know you said they taped up the door and the noise went away, but you should redo the test yourself. My leak was in the same place as the attached image (red). It disappeared when i taped up the mirror. It sounded like the wind was coming in over my ear. My suggestion would be for you to tape up your mirror, go for a drive and see. If it stops, you know you have a leak here. I used some gasket sealer between the door and gasket and the gasket and mirror (red line) and then opened the door, let down the window and wrapped tape around the window frame and mirror plastic to compress the gap and close it while the gasket sealer cured (blue line). It worked. Don't go messing with your hinges just yet.
You will be OK to retorque the existing bolts. For grease, it's a personal choice. thicker grease will attract dirt. but might give better results. Not to worry, we are all happy to help and provide suggestions. I hope it works out for you.
Well, I'm not sure where an extra turn with the breaker bar will put the final torque at. Just be careful you don't stretch the bolts. Here's a link of how to lube the pads. You can inspect them to make sure they are there while you're lubing them. Make sure they are clean before lube. Part number could be 84474225 https://static.nhtsa.gov/odi/tsbs/2017/MC-10139210-9999.pdf
60ft lb is not the correct torque. Correct me if I'm wrong, you're supposed to torque to 59 ft lb, then put a breaker bar on, and rotate the nut another 130 degrees for final torque. Try this. If it persists, you might have worn isolation pads on the spring tips. They can be relubed or replaced easily enough.
Super long extensions on my ratchet.
Ok! Do you open the 15mm bolt and completely remove it or just slide it down?
I'm going to have to have a look ar this. I just got a 14 for work and the noise is driving me nuts. 180K Km on it. My 16 has had it creep back in the last 3 weeks. Prior to this I pumped some grease in from outside it. I'm going to try some gm lube on the inside of the boot, and wrap it with some dynamat to see if theres any difference. I'm not interested in going to a dealer with my 16 - too much hassle!!
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