Bump...just coz I posted about my audio issues today too...same door.
I'm still without a clue. You mentioned swapping a door card...what is that?
Also, why was the door unaligned in the first place...prior accident?
If there's a connection right inside that boot to the door, then maybe when they did whatever, that loosened up? I'll have to look in mine and see what's there, though I seem to have lost my left rear speaker too...so I'm considering a failure in a channel...
Hope you figure yours out...if I run into anything that might help, I'll let you know.
Upcoming comedy shows: May 20, Greenwich Village Comedy Club. 6 p.m. See Facebook for other shows and PM me if you can make one...love to see you there!
A recent set: https://youtu.be/995gLmVEVZk
Mangofy your E46!