Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate or Replace Intermediate Shaft as Appropriate)

This bulletin is being revised to include I-shaft part number (P/N 25829293) for the 2000-2005 Monte Carlo. Please discard Corporate Bulletin Number 01-02-32-001I (Section 02 -- Steering).

Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel.

This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise.

Important: This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern.

Engineering Investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigations shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease may temporarily eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return.

Attempt to duplicate the customer's concern and isolate the I-shaft by following the procedure below:

1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle.
2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn.
3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface.
4. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft -- not the steering gear. Continue with the correction.

2000-2007 Chevrolet Impala, Monte Carlo

2004-2007 Pontiac Grand Prix

2001-2004 Buick Regal

1998-2002 Oldsmobile Intrigue

2005-2007 Buick Allure (Canada Only), LaCrosse

Important: Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft.

Replace the existing steering intermediate shaft using the service procedure found in Service Information.

The remaining vehicles listed below will still need to have the current I-shafts re-lubricated. New I-shafts will be released later in 2007 for some of the remaining vehicles.

1997-2005 Chevrolet Cavalier

1997-2005 Pontiac Sunfire

Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below.

1. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft Replacement in the appropriate Service Manual.



2. Fully extend the intermediate shaft by pulling the two shafts apart.



3. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe.



4. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening.



5. Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in.




Important: Make sure the intermediate shaft is being pressed over the ears of the solid shaft.

6. Use a hard surface to ease the collapse of the intermediate shaft. It is best to use a pumping action when collapsing the shaft. Collapse the shaft as far as possible.
7. Remove the rubber stopper plug from the yoke end of the shaft.



8. Slowly extend the intermediate shaft apart.



9. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines.
10. Repeat Steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines.

Important: Before installing the intermediate shaft in the vehicle, make sure to stroke and extend the intermediate shaft at least 15 TIMES to completely lubricate the internal surface of the slip joint.

11. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in the appropriate Service Manual.

For vehicles repaired under warranty, use: