I thought I was crazy. The 2000 SSEi I had had this weird steering issue and now the 2002 SSEi has the same thing, but somewhat less. I see from these messages that many of you have the same issue. Thanks for the information on what the problem is. I'll be interested in the recall to get the 2002 fixed.

Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation (Replace Intermediate Steering Shaft) #04-02-35-004B - (Jul 27, 2004)
Clunk Noise from Front of Vehicle During Turning Maneuver/Steering Wheel Rotation (Replace Intermediate Steering Shaft)
2001-2004 Buick Regal

2001-2004 Cadillac Seville -- with RPO JL4 (Control Active Brake)

1997-2004 Chevrolet Cavalier

2000-2004 Chevrolet Impala, Monte Carlo

1997-2004 Pontiac Sunfire

2000-2004 Pontiac Bonneville

2003-2004 Pontiac Grand Prix

This bulletin is being revised to update model and part information. Please discard Corporate Bulletin Number 04-02-35-004A (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 may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop.

Cause
The clunk noise may be caused by a stick-slip condition in the intermediate shaft. An interaction with the steering system creates a vibration that travels up the steering column to the steering wheel.

Correction
DO THIS

Replace Intermediate Steering Shaft


A new intermediate steering shaft has been released to address the clunk noise.


Important
Engineering changes have been made to the Service Parts available through SPO. The Service Parts for the vehicles listed in this bulletin will no longer require lubrication of the Intermediate Steering Shaft.


Install a new shaft following the Intermediate Steering Shaft Replacement procedure in the Steering Wheel and Column sub-section of the Service Manual.

Parts Information
Part Number
Description

10367811
Shaft -- Intermediate Steering -- Bonneville / Seville

10377680
Shaft -- Intermediate Steering -- Cavalier / Sunfire

10376430
Shaft -- Steering Gear -- Impala

10376429
Shaft -- Steering Gear -- Monte Carlo / Regal

10376428
Shaft -- Steering Gear -- Grand Prix


Parts are currently available from GMSPO.

Can be bought at gm parts direct
GM PART # 10367811
CATEGORY: All
PACK QTY: 1 CORE CHARGE: $0.00
GM LIST: $136.51
OUR PRICE: $77.81

Intermediate Steering Shaft Replacement
Removal Procedure
1. Remove the steering column with the intermediate shaft attached.


2. Remove the intermediate shaft pinch bolt (2) at the steering column.
3. Remove the intermediate steering shaft (1).

Installation Procedure



1. Install the intermediate steering shaft (1) to the steering column.

2. Install the pinch bolt to the power steering gear stub shaft. Tighten
3. Tighten the power steering gear pinch bolt to 47 N·m (35 lb ft).
4. Install the steering column with the intermediate shaft attached. Refer to Steering Column Replacement[/img]

this is still in TSB phase right? No recall yet?

No recall yet, I dont think I would even get the recall at 120,000 miles on my car
Looking at doing it myself this winter?

My first real post on this site, I talked to a 20 year gm pontiac mechanic the other day, a guy that I know casually outside the dealer, he said you can remove the shaft without removing the steering column. What do you think? If the recall doesn't come through soon , I can't take the clunking much longer!

When i had this issue with mine, i lubed the shaft (no jokes please) and it has been fine for the last 15K miles or so. Have those of you with this issue tried that yet?

I too have had mine lubbed a couple of years ago and it has been clunk free.

I spoke to GM customer service about it and they told me that it won't be replaced unless the original symptoms return.

......so I keep cranking the wheel hoping it will make the clunk sound......

It'* true that the lube fix will work....for a while. I have a 2002 Bonneville and after having the rack & pinion replaced 2 years ago and having the "lube fix" done, The other day I started getting the clunk back, so I wouldn't assume that it is a fix all. It'* been about 20,000 miles