Cavalier L4-2.2L VIN F (2004)
Steering Shaft: All Technical Service Bulletins
Steering - Clunk Felt/Noise Heard From Steering Column
Bulletin No.: 07-02-32-006
Date: August 06, 2007
TECHNICAL
Subject:
Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation
(Lubricate Intermediate Shaft [I-Shaft])
Models:
1997-2005 Chevrolet Cavalier
1997-2005 Pontiac Sunfire
Condition
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.
Cause
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.
Diagnostic Tip
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 investigation 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:
Locate a large area (parking lot) where the vehicle can be turned in a tight circle.
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.
Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface.
If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft - not the steering gear. Continue the correction.
Correction
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.
Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft replacement in the appropriate Service Manual.
