Reduced Power Steering Assist, Excessive Steering Effort, Rubbing, Excessive Noise in Passenger Compartment (Reinstall/Replace Intermediate Shaft Lower Boot)

Some customers may comment on reduced power steering, excessive steering effort, rubbing or excessive noise in the passenger compartment.

The intermediate shaft lower boot between the bulk head and the steering gear may be incorrectly installed and interfering with the intermediate shaft.

Follow the diagnosis and service procedure below to correct this condition.

1. Lift the front wheels off the ground. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information. Refer to SI Document ID #692721.
2. With the ignition switch on and the engine off, have an assistant turn the steering wheel from right to left.
3. Grasp the intermediate shaft boot with either hand and while the steering wheel is being rotated, there should be no contact felt between the intermediate shaft boot and the intermediate shaft.

•	If no contact is felt but there is still a steering concern, refer to Symptoms - Steering Wheel and Column SI Document ID #805959.

•	If contact is felt, inspect the lower intermediate shaft boot for proper installation and damage.

•	If the boot is improperly installed with no damage to the boot, correctly reposition the boot.

•	If the boot is improperly installed and damaged, continue with the next step.

Notice: The front wheels of the vehicle must be maintained in the straight ahead position and the steering column must be in the LOCK position before disconnecting the steering column or intermediate shaft. Failure to follow these procedures will cause improper alignment of some components during installation and result in damage to the SIR coil assembly.

4. Turn the ignition OFF and remove the key from the ignition lock cylinder in order to lock the steering column.
5. Raise the vehicle.
6. Remove the left front tire. Refer to Tire and Wheel Removal and Installation, SI Document ID #664116.
7. Position the boot in order to provide access to the lower pinch bolt on the intermediate steering shaft.
8. Remove the lower pinch bolt from the power steering gear stub shaft .
9. Remove the intermediate steering shaft from the power steering gear stub shaft.
10. Slide the damaged lower boot out of the upper boot and off the intermediate shaft.
11. Install the new lower intermediate shaft boot into the upper boot. Refer to the parts chart below.
12. Position the intermediate steering shaft into place.

Important: Make sure the intermediate shaft is correctly sealed on the steering gear stub shaft before installing the pinch bolt.

13. Install the lower pinch bolt to the intermediate steering shaft at the steering gear.

Tighten
Tighten the pinch bolt to 48N·m(35 lb ft).

14. Install the lower boot onto the steering gear.
15. Reinspect to make sure the intermediate shaft is not contacting the boot.
16. Reinstall the left front tire. Refer to Tire and Wheel Removal and Installation, SI Document ID #664116.
17. Lower the vehicle.
18. Road test the vehicle.

Parts are expected to be available rom GMSPO on September 5, 2003. DO NOT order parts for stock. Parts are in limited quantities.

For Bulletin Use Only