KNOCKING NOISE HEARD AT LOW SPEEDS OVER ROUGH ROADS. Chevrolet Cavalier 1995

REVISION: 07/30/96

THIS BULLETIN IS BEING REVISED TO ADD THE 1996 MODEL YEAR AND REVISE THE "CORRECTION" PROCEDURE WHICH NOW INCLUDES SERVICE PARTS. PLEASE DISCARD CORPORATE BULLETIN NUMBER 53-32-02 (SECTION 3 - STEERING/ SUSPENSION). ---------------------------------------------------------------------- REVISION: 09/23/96

THIS BULLETIN IS BEING REVISED TO CORRECT THE VIN BREAKPOINT INFORMATION AND CORRECTION 1, STEPS 13 AND 15. PLEASE DISCARD CORPORATE BULLETIN NUMBER 53-32-02A (SECTION 3 - STEERING/ SUSPENSION). ----------------------------------------------------------------------

SUBJECT: KNOCKING NOISE HEARD AT LOW SPEEDS OVER ROUGH ROADS (REPLACE RACK BEARING OR INSTALL RESTRICTOR)

MODELS: 1995-96 CHEVROLET CAVALIER 1995-96 PONTIAC SUNFIRE

CONDITION:

SOME OWNERS MAY COMMENT ON A LOUD KNOCKING NOISE COMING FROM THE FRONT OF THE VEHICLE WHEN DRIVING BETWEEN 9 AND 12 MPH OVER ROUGH ROADS. THERE ARE TWO SEPARATE CAUSES AND CORRECTIONS FOR THIS GENERAL CONDITION.

CAUSE:

THE VIBRATIONS FROM THE SUSPENSION DAMPING THE ROUGH ROADS ARE BEING TRANSMITTED TO THE STEERING GEAR AND THROUGH THE POWER STEERING SYSTEM.

CORRECTION:

CORRECTION 1 -

VIN BREAKPOINTS:

PLANT CHEVROLET PONTIAC ===== ========= =======

LORDSTOWN T7231036 T7552727 LANSING TM123683 N/A GENASYS TB104216 TB202781 RAMOS TS863541 TS863551

A KNOCKING NOISE HEARD WHILE DRIVING STRAIGHT AHEAD INVOLVES 1995-96 VEHICLES BUILT PRIOR TO THE ABOVE VIN BREAKPOINTS. THIS CONDITION MAY BE CORRECTED BY REPLACING THE STEERING GEAR RACK BEARING AND SPRING WITH A SERVICE KIT, P/N 26063086.

USE THE FOLLOWING REPAIR PROCEDURE:

SEE FIGURE 1. (NUMBERS IN PARENTHESIS BELOW REFER TO CALLOUTS IN FIGURE.)

1. REMOVE STEERING GEAR (5). REFER TO SECTION 3B IN THE SERVICE MANUAL).

2. SECURE STEERING GEAR ON WORKBENCH.

3. WHILE HOLDING THE ADJUSTER LOCK PLUG (3) STATIONARY, LOOSEN THE ADJUSTER PLUG LOCKNUT (4) AND REMOVE.

4. REMOVE ADJUSTER PLUG (3).

5. REMOVE SPRING (2).

6. REMOVE BEARING (1).

7. INSTALL BEARING (1).

8. INSTALL SPRING (2).

9. INSTALL ADJUSTER PLUG (3).

10. TIGHTEN THE ADJUSTER PLUG (3) TO 15 N.M (11 LBS. FT.) (TURN CLOCKWISE). THEN BACK-OFF (TURN COUNTERCLOCKWISE) 45 DEGREES. REFER TO FIGURE 1.

11. WHILE HOLDING THE ADJUSTER PLUG (3) STATIONARY, REINSTALL AND TIGHTEN THE ADJUSTER PLUG LOCKNUT (4). TIGHTEN TO 60-90 N.M (44-66 LBS. FT.).

12. RECHECK THE STEERING GEAR TURNING TORQUE NOT TO EXCEED 2 N.M. (18 LBS. IN.). MAKE SURE THERE IS NO LUMPINESS OR BINDING WHEN TURNING STEERING SHAFT.

13. IF LUMPINESS, BINDING, OR TURNING TORQUE EXCEEDS 2 N.M (18 LBS. IN.), LOOSEN ADJUSTER PLUG, REPEAT STEP 10 AND SET THE BACK-OFF AT 50 DEGREES, THEN GO TO STEP 11.

14. REINSTALL THE STEERING GEAR (REFER TO SECTION 3B OF THE SERVICE MANUAL).

15. TEST VEHICLE FOR STEERING WHEEL RETURNABILITY.

CORRECTION 2 -

VIN BREAKPOINTS:

PLANT CHEVROLET PONTIAC ===== ========= =======

LORDSTOWN T7238432 T7556378 LANSING TM125285 N/A GENASYS TB104462 TB203007 RAMOS TS870636 TS870637

A KNOCKING NOISE HEARD WHILE TURNING AND DRIVING OVER A BUMP AT THE SAME TIME INVOLVES 1996 VEHICLES WITH 2.2L ENGINES (VIN 4 - RPO LN2) BUILT PRIOR TO THE ABOVE LISTED VIN BREAKPOINTS. THIS CONDITION MAY BE CORRECTED BY INSTALLING A POWER STEERING RESTRICTOR VALVE, P/N 22592200, INTO THE PUMP RESERVOIR INLET. RESTRICTOR CAN ONLY BE INSTALLED ON VEHICLES EQUIPPED WITH POWER STEERING COOLER PIPES.

USE THE FOLLOWING INSTALLATION PROCEDURE:

1. INSPECT VEHICLE TO INSURE VEHICLE IS EQUIPPED WITH A POWER STEERING COOLER PIPE.

2. INSTALL RESTRICTOR IN THE INLET TUBE OF THE POWER STEERING FLUID RESERVOIR.

3. RESTRICTOR SHOULD BE PUSHED IN BY HAND UNTIL SNUG, NOT FORCED OR HAMMERED.

4. RETURN HOSE SHOULD BE PUSHED OVER THE RESTRICTOR AND INLET TUBE, THEN CLAMPED.

PARTS INFORMATION:

PARTS ARE EXPECTED TO BE AVAILABLE JUNE 10, 1996.

WARRANTY INFORMATION:

FOR VEHICLES REPAIRED UNDER WARRANTY, USE:

LABOR OPERATION NUMBER DESCRIPTION LABOR TIME =============== =========== ==========

CONDITION 1 -

E9700 ADJUST USE PUBLISHED LABOR TIME

E9720 GEAR R & R 1.3 HR

CONDITION 2 -

E8623 INSTALL RESTRICTOR .2 HR

FIGURES: 01 ATTACHMENTS: 00

Object Number: 93902 Size: FS

GENERAL MOTORS BULLETINS ARE INTENDED FOR USE BY PROFESSIONAL TECHNICIANS, NOT A "DO-IT-YOURSELFER". THEY ARE WRITTEN TO INFORM THOSE TECHNICIANS OF CONDITIONS THAT MAY OCCUR ON SOME VEHICLES, OR TO PROVIDE INFORMATION THAT COULD ASSIST IN THE PROPER SERVICE OF A VEHICLE. PROPERLY TRAINED TECHNICIANS HAVE THE EQUIPMENT, TOOLS, SAFETY INSTRUCTIONS AND KNOW-HOW TO DO A JOB PROPERLY AND SAFELY. IF A CONDITION IS DESCRIBED, DO NOT ASSUME THAT THE BULLETIN APPLIES TO YOUR VEHICLE, OR THAT YOUR VEHICLE WILL HAVE THAT CONDITION. SEE A GENERAL MOTORS DEALER SERVICING YOUR BRAND OF GENERAL MOTORS VEHICLE FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.