Ok..been racking my brain here and remembered from my days at Chevy about this bulletin..
This may apply to your vehicle/may not...worth looking into.....
Here is part of the bulletin..I didn't print the instructions cause its quite long...but basically the instrument panel has to removed to access the tie bar..I'll print step 25....the rest is R & R procedures...
<<<25. Loosen the tie bar fasteners, align the tie bar as shown and tighten the tie bar fasteners.>>>>>>
Let us know....Good luck..Hope this is it......
File In Section: 08 - Body and Accessories
Bulletin No.: 00-05-49-003
Date: June, 2000
Rattle/squeak In Right Side of Instrument Panel or Right Front Door Trim Panel Scratched or Right Side End of instrument Panel Contacting Door Trim Panel (Remove instrument Panel Assembly and Align Tie Bar) Models:
1995-2000 Chevrolet Cavalier
1995-2000 Pontiac Sunfire Condition
Some customers may comment on: ^ A rattle or squeak type sound coming from the right side of the instrument panel near the right front door. ^ A scratch or wear mark on the right front door trim panel towards the front of the vehicle. ^ The right side end of the instrument panel contacting or rubbing against the right front door trim panel. Cause
The tie bar under the instrument panel may not be correctly aligned to the body sheet metal. The tie bar may also be referred to as the instrument panel carrier support bar or cross vehicle beam. Correction Notice:
Do not attempt to align by prying or forcing the instrument panel assembly to the left side of the vehicle. Doing so will result in damage to the instrument panel assembly, components, door and/or door trim panel.
Remove the instrument panel and align the tie bar to the body sheet metal