Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation (Lubricate Intermediate Shaft)

This bulletin is being revised to include the 2005 model year. Please discard Corporate Bulletin Number 04-02-35-008 (Section 02 -- Steering).

Some customers may comment on a clunk type noise coming from the front of the vehicle 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. Typically, the clunk noise will be heard once for every 180° of steering wheel rotation in either direction. This clunk noise may also 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.

Remove the intermediate steering shaft from the vehicle and lubricate the shaft using Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure contained in this bulletin.

Important: It is not necessary to replace the following parts:

Notice: The wheels of the vehicle must be pointed straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the SIR coil to become uncentered, which may cause damage to the SIR coil assembly.

1. Remove the steering intermediate shaft from the vehicle. Refer to "Intermediate Steering Shaft Replacement" procedure in the appropriate Saturn L-Series Service Manual or SI.



2. Mark intermediate shaft with marker or grease pencil to ensure proper indexing of joints if shaft comes apart.
3. Fully extend the intermediate shaft by pulling the two shafts apart.



4. Apply the grease supplied in the Steering Column Shaft Lubrication Kit, P/N 26098237, in the aluminum end of the yoke opening. Place the syringe tip as deep as possible into the yoke and dispense the full contents of the syringe into the yoke.



5. Install the rubber stop plug from the Steering Column Shaft Lubrication Kit, P/N 26098237, into the yoke opening.



6. Secure the rubber plug by inserting a 3/8" (9.5 mm) round shaft between rubber plug and the yoke.




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

7. 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.
8. Slowly extend and collapse the slip joint fully. Repeat 15 times to distribute the grease.



9. Slowly extend the intermediate shaft apart.



10. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease past the shaft splines.
11. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is past the shaft splines.
12. Remove the rubber stopper plug from the yoke end of the shaft.

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

13. Reinstall the intermediate shaft into the vehicle. Refer to the "Intermediate Steering Shaft Replacement" procedure in the appropriate Saturn L-Series Service Manual or SI.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for E7700 R&R Shaft Steering Intermediate. An ADD time will be included for lubricating the intermediate shaft.