Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly) (00-02-35-003N)

Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly)

TECHNICAL SERVICE BULLETIN

Condition

Some customers may comment on a clunk-type noise coming from under the hood that also can be felt  in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces.

Diagnostic Tips

Use the information below to help diagnose the source of the noise.

• The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column. 
• Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD  and is typically louder with the windows rolled down. For additional information, refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember, Change Fastener Orientation).
• Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT  in the steering wheel and/or steering column area, typically while driving on rough road surfaces with steering wheel input.

Correction

Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise using the procedure listed below.

1. Set the front wheels in the straight ahead position.
   NOTE: On the 2002 and later model year vehicles, the steering column LOCK was removed from the steering column. It is critical that the J 42640 - Steering column Anti-Rotation Pin is used when servicing steering columns on 2002 and later model year vehicles. Failure to use the J 42640 may result in damage to the SIR coil.
2. Set the steering wheel in the LOCK position on 2001 and prior model year vehicles.
Fig 1: Using J 42640
Courtesy of GENERAL MOTORS CORP.
3. For 2002 and later vehicles, install the J 42640 in the steering column lower access hole.
Fig 2: View Of Lower Shaft To Upper Shaft Bolt
Courtesy of GENERAL MOTORS CORP.
4. From under the hood, remove the lower bolt that connects the upper intermediate shaft to the steering gear coupling shaft.
5. Slide the shaft towards the dash in order to disengage the shaft from the steering gear coupling shaft.
6. For vehicles equipped with adjustable foot pedals, perform the following steps:
   1. Reposition the carpet away from the accelerator pedal position (APP) sensor.
   2. Remove the two nuts retaining the accelerator pedal to the bulkhead.
   3. Reposition the accelerator pedal out of the way so the intermediate shaft can be removed.
Fig 3: View Of Upper Intermediate Steering Shaft
Courtesy of GENERAL MOTORS CORP.
7. From inside the vehicle, remove the upper bolt from the upper intermediate steering shaft (1) to the steering column connection.
8. Remove the upper intermediate steering shaft assembly.
   1. From inside the vehicle, slide the shaft down and off the steering column.
   2. From inside the vehicle, slide the upper intermediate shaft through the dash boot seal and remove the shaft from the vehicle.
9. Replace the upper intermediate shaft.
10. Install the upper intermediate steering shaft through the dash boot seal and slide the lower end into the steering gear coupling shaft.
11. Raise the upper end of the intermediate steering shaft and install into the steering column shaft.
12. Install the upper bolt and nut.

    Tighten:   Tighten the bolt to 47 N.m (35 lb ft).

13. Install the lower bolt and nut.

    Tighten:   Tighten the bolt to 50 N.m (37 lb ft).

14. For vehicles equipped with adjustable foot pedals, perform the following steps:
    1. Reposition the accelerator pedals into position on the bulkhead.
    2. Install the two retaining nuts.

       Tighten:   Tighten the nuts to 20 N.m (15 lb ft).

    3. Reposition the carpet into place.

Parts Information

Warranty Information

For vehicles repaired under warranty, use: