Well I finally figured out that the crackling styrofoam type noise is coming from the pillar right by the drivers left ear where the air bag plaque is located. Back to the dealer to see if they can get it fixed this time.
Wilol update when I get car back.

 

I have that SAME ISSUE! They've replaced the rear speaker twice, the speaker grille once... and nothing.

The loaner I have today after dropping my car off has the same issue. What's the fix?

 

The noise you both are describing is coming from the Driver pillar in the center were the seat belt is coming of correct. At the top, the pillar is probably somehow making contact with the headliner. Try putting something thin, like a dollar bill, then slide it between the pillar and the headliner at the top, then see if the noise goes away.

 

Hi guys,
I posted a fix for that one. The cause for this noise is so ridiculously minor it's almost a joke. In case your dealer hasn't figured it out, search my posts and you'll find the fix. Your dealer can do it in about 20 min.

 

Just checked all your posts and did not see the fix for the pillar noise.
Mind posting it here again?

 

Here it is:

I took care of it myself. I found it. The roof liner is touching / rubbing a little metal bracket just ever so slightly. It't the bracket holding the B Pilar cladding on top. I removed B Pilar Cladding (pop out the little airbag plastic sign on top, remove torx inside, then pop pop off cladding). I simply put a little double sided tape between headliner and bracket WITHOUT removing plasting on one sticky side. I also put some white grease in. Now, when it touches, there is no friction and no noise. Attention....it is easy to let the torx screw inside the frame, belt ect. Just pull out carefully.
It is a very easy fix.

The bracket I am refering to is a little tab which the B Pillar cladding is sliding into on top. There are two of those tabs. It is where the headliner touches the tab where the noise is generated from.