Don't know if this is a repost.

EI05093 - Clunk Noise in Steering System at Slow Speeds While Turning and/or Driving Over Bumps (Replace Intermediate Shaft) #05-02-32-005C - (Jan 20, 2006)EI05093 -- Clunk Noise in Steering System at Slow Speeds While Turning and/or Driving Over Bumps (Replace Intermediate Shaft)
2005-2006 Chevrolet Cobalt

2006 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2003-2006 Saturn ION

This bulletin is being revised to add additional models and parts information. Please discard Corporate Bulletin Number 05-02-32-005B (Section 02 - Steering).

Condition
Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning maneuver. This condition can 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 90° 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.

The following are characteristics of this noise:

• This noise is very random.

• This noise is independent of the steering wheel angle and independent of the bumpiness of the road.

• This noise is a low frequency dull one and can be felt in your feet.

• This noise can normally be heard from the driver seat.

• This noise can be felt upon touching the steering gear from outside of the vehicle.

Note that you might also notice a slight scrub-type noise when turning the wheel back and forth. This type of noise is considered normal and repairs will not eliminate it.

Cause
This condition may be caused by inadequate lubrication of the steering intermediate shaft.

Correction
DO NOT REPLACE THE STEERING GEAR OR STEERING COLUMN ASSEMBLY.

Replace the intermediate shaft.

Parts Information
Part Number
Description
Qty

10394225
Shaft, Intermediate Steering (Cobalt/Pursuit)
1

10392744
Shaft, Intermediate Steering (ION)
1

22730246
Shaft, Intermediate Steering (HHR)
1


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7700
Shaft, Steering Intermediate - Replace
Use Published Labor Operation Time




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