This thread was very helpful with the steering issue on my 03. Since buying my SSEi (23k miles) a couple of months ago, I've noticed that steering noise. I printed the info from this thread and took it to the dealer today. (bought the extended warranty)
The service advisor acknowledged it was the same problem as described. They checked if anyone had the newly designed part but it can't be found. There is no date for availability on this part. The dealer just lubed the shaft as a temporary fix. A couple hours later the noise came back.
I find it odd that this new part is so unavailable and this issue is on so many vehicles.

GM issued a new bulletin since #06-02-35-010, the new one #01-02-32-001G (which was released exactly 14 days after the one your referring to) states that dealers are again to lube the shaft and not replace it.

It'* a band aid solution, but GM claims the new grease is a better lubricant and will take care of the concern.

GM is not overly concerned with the issue because it is not a safety problem...it'* just an annoyance. The shaft will NOT fail and cause a loss of steering, so it is not a safety issue.

I know, it sucks! But please don't blame your dealership, they have no say in it. All they can do is what GM will allow them to do. A lot of people don't take that into consideration and they get mad at their dealer.

Thanks Motorhead for that valuable info. I was a little confused by the events today and wondering why the dealer/GM did what they did.
It makes sense the way you stated it as far as the resolution. Before knowing that, I was thinking I didn't want to be stuck with a major repair later, especially after the extended warranty expires.

Well, if they lubed your shaft ( ) and it still clunks, then either they didn't do it right or you have a problem in the rack and pinion steering unit.

Motorhead - can you post the contents of that bulletin? I still show the bulletin originally posted as valid, and can't find anything on the bulletin number you have by searching Google. Is that something that GM is releasing only to dealers and no where else?

FWIW - every shaft that i've witnessed with a problem, it has been the top u-joint that is binding...not the shaft.

The content of this is all messed up, but this is the way it pasts on the web...and I just don't feel like correcting all the errors.



Document ID# 1831735

Subject:
Clunk Felt/Noise Heard from Steering Column, Steering Gear and/or Front of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate Intermediate Shaft) #01-02-32-001G - (05/25/2006)
Models: 2001-2004 Buick Regal
2005-2006 Buick Allure (Canada Only), LaCrosse
1997-2005 Chevrolet Cavalier
2000-2006 Chevrolet Impala, Monte Carlo
1998-2002 Oldsmobile Intrigue
1997-2005 Pontiac Sunfire
2004-2006 Pontiac Grand Prix


This bulletin is being revised to remove the Cadilac Seville, Oldsmobile Aurora and Pontiac Bonneville models. Please discard Corporate Bulletin Number 01-02-32-001F (Section 02 - Steering).


Condition

Some customers may comment on a clunk type noise coming from the front of the vehicle while driving 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. Some vehicles may only exhibit the noise once for every 360° of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel.

Cause

This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a "slip stick" condition possibly resulting in the clunk noise.

Diagnostic Tip

Important: This condition is commonly misdiagnosed as originating in the steering gear and has resulted in the replacement of numerous steering gears without correcting the concern.
Engineering Investigation shows that numerous steering gears have been misdiagnosed and replaced. The investigations shows that if the technician incorrectly diagnoses the steering gear as the cause of the noise and/or clunk during replacement of the steering gear, the technician may stroke and/or cycle the I-shaft, distributing the original grease in the I-shaft. This distribution of the original I-shaft grease temporarily may eliminate the I-shaft clunk so that the technician believes the noise and/or clunk is corrected with the steering gear replacement and returns the vehicle to the customer. After the customer drives the vehicles for several miles and dissipates the original grease, the noise may return.
Attempt to duplicate the customer'* concern and isolate the I-shaft by following the procedure below:
1. Locate a large area (parking lot) where the vehicle can be turned in a tight circle.
2. Turn the steering wheel to the right and/or left all the way to the steering lock, then off the steering lock a 1/4 turn.
3. Drive the vehicle approximately 5 km/h (3 mph) in a circle, preferably over rough pavement or seams on the road surface.
4. If a clunk is felt in the steering wheel, the MOST likely cause is the I-shaft -- not the steering gear. Continue with the correction.

Correction

DO THIS DON'T DO THIS
Lube the Intermediate I-Shaft with Grease Kit P/N 26098237 DO NOT Replace the Intermediate I-shaft
P/N 15243954
P/N 26078302
P/N 26100571
P/N 10367811
P/N 10376430
P/N 10376429
P/N 10376428
P/N 10377680
Remove the intermediate steering shaft from the vehicle and lubricate the shaft with a Steering Column Shaft Lubrication Kit, P/N 26098237. Follow the service procedure listed below.
1. Remove the steering intermediate shaft from the vehicle. Refer to Intermediate Steering Shaft Replacement in the appropriate Service Manual.


2. Fully extend the intermediate shaft by pulling the two shafts apart.


3. Apply the grease supplied in the Steering Column Shaft Lubrication Kit in the aluminum end of the yoke opening. Direct the syringe tip as deep as possible into the yoke and dispense the full content of the syringe.


4. Install the rubber stop plug from the Steering Column Shaft Lubrication kit into the yoke opening.


5. Secure the rubber plug by swinging the upper yoke 90°. One ear of the yoke should press the rubber plug in.


Important: Make sure the intermediate shaft is being pressed over the ears of the solid shaft.
6. 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.
7. Remove the rubber stopper plug from the yoke end of the shaft.


8. Slowly extend the intermediate shaft apart.


9. Inspect the intermediate shaft for a minimum of 5 mm (0.2 in) (a) of grease on the shaft splines.
10. Repeat steps 4-9 if less than 5 mm (0.2 in) of grease is on the shaft splines.
Important: Before installing the intermediate shaft in the vehicle, make sure to stroke and extend the intermediate shaft at least 15 TIMES to completely lubricate the internal surface of the slip joint.
11. Reinstall the intermediate shaft into the vehicle. Refer to Intermediate Steering Shaft Replacement in the appropriate Service Manual.

Parts Information

Part Number Description
26098237 Steering Column Shaft Lube Kit

Thanks, Motorhead. I appreciate you doing that. Now, I'm more confused than ever when it comes to it. The original TSB (06 02 35 010) refers to the one you pointed out..and says in part...

...yet when I tried to find information on it, I couldn't. With what you've posted, it would appear that your TSB says to lube the shaft except for the 3 vehicles listed above which had been removed from that bulletin....I think. At least the way it seems to sorta make sense to me...the TSB 06 02 35 010 is still valid for our cars, which is replace the intermediate shaft with the "new" one, but the cars listed in 01 02 32 001G still get the lube job.

Does GM do that on purpose just to confuse things?

Archon, I believe you are right after further investigating this concern. The original bulletin you posted is still active. This means that the Bonneville (2000-2005) should receive a new shaft and NOT a lube kit.
I was told about six months ago from my superior that GM sent a letter to ALL GM DEALERS stating that "ABSOLUTELY NO VEHICLE WAS TO HAVE THE SHAFT REPLACED (CAR OR TRUCK) UNLESS IT WAS DAMAGED BY COLLISION." I didn't think much of it and I did what I was told.

Now that I look into it, it does indeed seem that the bulletin you referred to is still an active bulletin? I think I need to have a talk with my superior.

Thank you Archon for pointing this out to me. I do know that we see VERY few Bonnevilles with the steering shaft cluck concern so this must not be too big of an issue on the Bonnevilles. We do see a LOT of full size trucks with this concern and some cars, but less cars than trucks...and almost no Bonnevilles.

Thanks for checking further into that, motorhead. We used to have quite a few posts on it, but that has dropped off quite a bit. I'm not sure why.

Doing what your boss tells you to do helps to keep you employed.

Yeah, it sucks, but I need a pay check.