SATURNS: CLUNK RATTLE, OR BUZZ NOISE COMING FROM FRONT. Saturn SL1/SC1/SW1 1997

SUBJECT: CLUNK, RATTLE OR BUZZ NOISE COMING FROM FRONT OF VEHICLE (ADJUST STEERING GEAR PRELOAD, OR REPLACE INTERMEDIATE STEERING SHAFT, OR REPLACE STEERING COLUMN)

MODELS AFFECTED: FOR CONDITION 1: 1991-1998 SATURNS FOR CONDITION 2: 1995-1996 SATURNS FOR CONDITION 3: 1995-1997 SATURNS AND 1998 SATURNS UP TO AND INCLUDING VIN WZ166759

CONDITION:

CUSTOMERS MAY COMMENT ABOUT ONE OR MORE OF THE FOLLOWING CONDITIONS: 1. CLUNK NOISE FROM STEERING GEAR. THIS NOISE MAY BE PRESENT WHEN DRIVING OVER LARGE VARIATIONS IN PAVEMENT SUCH AS 25-75 MM (1-3 IN.) BUMPS AT 8-16 KM/H (5-10 MPH). AN EXAMPLE IS WHEN BACKING OUT OF A DRIVEWAY, OVER A CURB THAT HAS A 25-75 MM (1-3 IN.) DROP. 2. RATTLE NOISE FROM INTERMEDIATE STEERING SHAFT. THIS NOISE MAY BE PRESENT WHEN DRIVING OVER MODERATE VARIATIONS IN PAVEMENT SUCH AS 25 MM (1 IN.) BUMPS AT 10-40 KM/H (10-25 MPH). AN EXAMPLE IS WHEN DRIVING OVER BROKEN PAVEMENT OR LARGE GRAVEL. THE CUSTOMER MAY COMMENT THAT THE STEERING WHEEL WAS MOVING FROM SIDE-TO-SIDE WHEN THE NOISE WAS PRESENT. 3. BUZZ NOISE FROM STEERING COLUMN. THIS NOISE MAY BE PRESENT WHEN DRIVING OVER SMALL VARIATIONS IN PAVEMENT 13-25 MM ([emsp ]-1 IN.) BUMPS AT 24-40 KM/H (15-25 MPH). AN EXAMPLE IS WHEN DRIVING OVER A PAVED ROAD COVERED WITH LOOSE GRAVEL OR WHEN DRIVING ON A GRAVEL ROAD. THIS NOISE MAY BE PRESENT AT A SPECIFIC ANGLE OF THE STEERING WHEEL.

CAUSE:

THESE CONDITIONS MAY BE CAUSED BY ONE OF THE FOLLOWING CONDITIONS: . CONDITION 1 (CLUNK NOISE FROM STEERING GEAR), MAY BE CAUSED BY INSUFFICIENT STEERING GEAR PRELOAD. . CONDITION 2 (RATTLE NOISE FROM INTERMEDIATE STEERING SHAFT), MAY BE CAUSED BY EXCESSIVE PLAY IN THE INTERMEDIATE STEERING SHAFT UNIVERSAL JOINTS. . CONDITION 3 (BUZZ NOISE FROM STEERING COLUMN), MAY BE CAUSED BY EXCESSIVE LASH IN LOWER STEERING COLUMN BEARING.

CORRECTION:

SINCE THE NOISES ARE ROAD SURFACE AND SPEED DEPENDENT, IT IS IMPORTANT TO ROAD TEST THE VEHICLE TO VERIFY THE CONCERN. REFER TO THE PROCEDURES IN THIS BULLETIN TO LOCATE AND REPAIR CONDITIONS IN THIS BULLETIN.

--------------------- ATTACHEMENT ---------------------

PROCEDURES:

CONDITION 1 - CLUNK NOISE FROM STEERING GEAR - 1991-1998 SATURNS DRIVE VEHICLE OVER 25-75 MM (1-3 IN.) BUMPS AT 8-16 KM/H (5-10 MPH). IF THE CLUNK IS PRESENT ADJUST THE STEERING GEAR PRELOAD ACCORDING TO THE FOLLOWING PROCEDURE. IMPORTANT: MAKE ADJUSTMENT WITH FRONT WHEELS RAISED AND STEERING WHEEL CENTERED.

--------------------- FIGURE --------------------- 1. LOOSEN ADJUSTER PLUG LOCK NUT ON STEERING GEAR HOUSING. 2. TURN ADJUSTER PLUG CLOCKWISE UNTIL IT BOTTOMS IN STEERING GEAR HOUSING. 3. TIGHTEN ADJUSTER PLUG. TORQUE: 12 N.M (106 LB IN) 4. BACK-OFF ADJUSTER PLUG 50 DEGREES, PLUS OR MINUS FIVE DEGREES (SLIGHTLY LESS THAN ONE FLAT OF NUT). 5. TORQUE ADJUSTER PLUG LOCK NUT WITH A CROWS FOOT WRENCH, WHILE HOLDING ADJUSTER PLUG STATIONARY. TORQUE: 70 N.M (52 LB FT) 6. AFTER ADJUSTMENT, CHECK STEERING WHEEL RETURNABILITY.

CONDITION 2 - RATTLE NOISE FROM INTERMEDIATE STEERING SHAFT - 1995-1996 SATURNS 1. DRIVE VEHICLE OVER A 25-51 MM (1-2 IN.) BUMPS AT 10-40 KM/H (10-25 MPH). WHILE DRIVING OVER THE BUMPS, LIGHTLY HOLD THE STEERING WHEEL. THE STEERING WHEEL MAY BE ROTATING FROM SIDE-TO-SIDE WHEN THE NOISE IS PRESENT. 2. WHEN THE NOISE IS PRESENT, IT CAN BE DAMPED BY GRASPING THE STEERING WHEEL TIGHTLY AND NOT ALLOWING IT TO MOVE FROM SIDE-TO-SIDE. 3. IF THE NOISE IS PRESENT, RAISE VEHICLE ON HOIST. 4. INSPECT INTERMEDIATE STEERING SHAFT UNIVERSAL JOINTS TO DETERMINE IF THE VEHICLE IS EQUIPPED WITH A 1ST DESIGN INTERMEDIATE STEERING SHAFT. THE 1ST DESIGN INTERMEDIATE STEERING SHAFT UNIVERSAL JOINT BEARING CAPS ARE FLUSH WITH THE UNIVERSAL JOINT. THE 2ND DESIGN INTERMEDIATE STEERING SHAFT UNIVERSAL JOINT BEARING CAPS ARE RECESSED INTO THE UNIVERSAL JOINT. --------------------- FIGURE --------------------- 5. IF THE VEHICLE IS EQUIPPED WITH THE 1ST DESIGN INTERMEDIATE STEERING SHAFT, REPLACE THE INTERMEDIATE STEERING SHAFT WITH THE 2ND DESIGN INTERMEDIATE STEERING SHAFT ACCORDING TO "INTERMEDIATE SHAFT" PROCEDURES IN THE STEERING" SECTION OF THE APPROPRIATE YEAR "CHASSIS SERVICE MANUAL". 6. IF THE VEHICLE IS EQUIPPED WITH THE 2ND DESIGN INTERMEDIATE STEERING SHAFT, REFER TO MANUAL OR POWER STEERING DIAGNOSIS IN THE "STEERING" SECTION OF THE APPROPRIATE YEAR "CHASSIS SERVICE MANUAL"

CONDITION 3 - BUZZ NOISE FROM STEERING COLUMN - 1995-1997 SATURNS DRIVE VEHICLE OVER A LOOSE GRAVEL SURFACE OR A SURFACE WITH SMALL VARIATIONS IN PAVEMENT, 13-25 MM ([emsp ]-1 IN.) BUMPS, AT 24-40 KM/H (15-25 MPH). THE NOISE MAY ONLY BE PRESENT AT A SPECIFIC ANGLE OF THE STEERING WHEEL. IT MAY BE NECESSARY TO TURN THE STEERING WHEEL OFF-CENTER WHEN DRIVING. THE STEERING WHEEL SHOULD BE HELD LIGHTLY TO DUPLICATE THE CONDITION. WHEN THE NOISE IS PRESENT, PRESSING INWARD ON THE STEERING WHEEL, TOWARD THE FRONT OF THE VEHICLE WILL REDUCE THE NOISE.

IF THE NOISE IS REDUCED, REPLACE STEERING COLUMN FOLLOWING PROCEDURE IN "STEERING COLUMN" IN STEERING" SECTION OF APPROPRIATE YEAR "CHASSIS SERVICE MANUAL."

IF THE NOISE CANNOT BE DUPLICATED, REFER TO THE "STEERING" SECTION OF THE "CHASSIS SERVICE MANUAL."

PARTS REQUIREMENTS:

21011597 SHAFT ASM-INTER STEERING 21060972 COLUMN ASM-STRG 21485277 THREADLOCKER-LOCTITE[emsp ] 242

CLAIM INFORMATION TO RECEIVE CREDIT FOR THIS REPAIR DURING THE WARRANTY COVERAGE PERIOD, SUBMIT A CLAIM THROUGH THE SATURN DEALER SYSTEM FOR: . E9600 (ADJUST MANUAL STEERING GEAR ASSEMBLY), . E9700 (ADJUST POWER STEERING GEAR ASSEMBLY), . E7700 (REPLACE INTERMEDIATE STEERING SHAFT), OR . E7680 (REPLACE STEERING COLUMN ASSEMBLY) IF ANOTHER PROCEDURE IS PERFORMED, REFER TO THE APPROPRIATE ELECTRONIC LABOR TIME GUIDE FOR THE CORRECT LABOR OPERATION CODE AND TIME.

ATTACHMENTS, 01 FIGURES, 02

SATURN 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 YOUR SATURN RETAILER FOR INFORMATION ON WHETHER YOUR VEHICLE MAY BENEFIT FROM THE INFORMATION.