Rattle Noise From Front of Vehicle While Driving Over Rough Roads When Vehicle is Hot (Adjust Steering Gear Pre-Load, Replace Adjuster Plug)

2004 Chevrolet Malibu vehicles are equipped with a new Electric Power Steering (EPS) system. This new system replaces the traditional hydraulic power steering assisted system. The steering gear is a standard manual rack and pinion system. For additional information, refer to the links.

Some customers may comment that while driving over certain rough road conditions, they hear a rattle noise from the front end of the vehicle. Some customers may also comment that they feel clunking in the steering wheel while hearing the noise. This condition is more likely to occur only when the vehicle is hot and will go away after the vehicle cools down.

Follow the service procedure below to correct this condition.

1. Position the steering wheel on center, with the wheels in the straight ahead position.
2. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in General Information, SI Document ID #1211728.



3. Clean the adjuster plug area with brake clean, or equivalent, and shop air.

Notice: 

•	Use caution when removing the plastic adjuster plug to capture the adjuster spring.

•	Apply pressure to the plug while removing.

4. Apply pressure to the adjuster plug while removing with a T-55 Torx Bit to insure capture of the adjuster spring.
5. Remove the adjuster plug and spring from the steering gear.
6. Remove the adjuster spring from the old adjuster plug.
7. Apply LOCTITE™, P/N 89021297, or equivalent, to the new adjuster plug, P/N 26091704, threads. Apply the LOCTITE™ on the first two or three threads in a 360 degree pattern around the adjuster plug.
8. Install the adjuster spring into the new adjuster plug.
9. Install the adjuster spring and plug into the steering gear.

Tighten
Tighten the adjuster plug to 6 N·m(53 lb in).

10. Clean any excess LOCTITE™ from the adjuster plug area.
11. Lower the vehicle
12. Road test the vehicle and evaluate for proper steering returnability.

Parts are currently available through General Motors of Mexico.

For vehicles repaired under warranty, use:

*This labor op code only applies to this bulletin and will not be published in the current Labor Time Guide.