Being curious, I decided to take apart the intermediate shaft that I took out of my car last year. The shaft did not seem to be the problem, but the top U-joint did not move freely. I took the U-joint apart, and found that one of the bearing caps was pretty well bound up, while the other one moved freely. I could move one with my fingers. The other I had to use pliers in order to turn it. It seems that one part of the shaft takes most of the stress, and either the bearings or the race wore out. The cross section was fine. It didn't matter which end of the cross I put the cap on, the problem stayed with the cap. This could explain why lubing the shaft doesn't always solve the problem. I hope that GM works on making the U-joint stronger, and does not just focus on the shaft.

Man, I haven't encountered the problem yet, but that was good information! Stupid question Obviously lubing the old shaft doesn't address the real problem, but does the replacement shaft include the u-joint(*) in question?

I can not say for certain, but everything on the new shaft that I purchased looked just like the old one that I just took apart. And, it lasted less than a year before it started to make noise again. I just had it replaced under the GM parts warranty. I made it by 5 days. If I had to guess, I'd say that it has the same U-joints.

Sounds like you may have hit on the real problem.

Well, it become interresting...are able to take a pic of that part?
it could be good to see it, i have no idea of what it look like


good update archon.

I took some pictures as I was moving along taking it apart. It had separated the two sections before I started the project. I don't have a picture right now of the whole assembly, but I can at least show you where the problem was. This is of the upper part of the shaft - the part that attached to the steering column. The part of the cross that attaches to the shaft was where the problem was. I'll see if I can get a picture of the bottom half some time this weekend.

http://pg.photos.yahoo.com/ph/archon...31.jpg&.src=ph

Here'* the picture of the lower half of the intermediate shaft laid next to part of the upper. The lower U-joint if pretty rusty as when they put the shaft in, they never pulled the boot back down. The joint still moves freely.

http://pg.photos.yahoo.com/ph/archon...44.jpg&.src=ph

so thats that U joint that make the noise?

The top U-joint in the first picture was the one making the noise. The bottom rusty one was fine.