Well, I don't particularly enjoy annoyances and would prefer that the car did not have this defect. From what I have read it reoccurs no matter what actions or repairs are taken. I have a mechanic that said he was going to take the steering shaft out and basically remove/alter/rebuild the defective section. The part itself only runs like 160 bucks... he will not charge me as much as the dealership would to install a new one. I contacted a local dealership about them replacing it for free, but they have not gotten back with me with an answer... I wont be holding my breath. lol
Guess it is good to know some mechanics

Dont turn the wheel so hard and it wont wear so quickly.......Not helping am I. In the same Boat Christy, so dont take it hard. I'm trying to laff with you.

Just my opinion here, but I feel GM engineers the angle of the steering shaft at to hard an angle. And they can redesign the part all they want and not come up with a lasting cure.

If your mechanic will do it cheaper and the dealer wont cover it, then by all means go that route. But I would jusr have him put new parts in, same as the dealer, the repair is going to last the same either way. The new shaft seems to work longer, but we still hear of new clunks.

As far as fabricating an IM Shaft,...... I'd be real nervous. It'* a complicated set of parts. Your life is literally in the hands on the steering wheel. If GM faced with the cost they have put out for alot of problems with this shaft, cant redesign one better, I wouldnt trust it to a garage mechanic.

Im just going to buy the part and have my mechanic put it in.. he will do it for free, I just have to buy the part. He is going to look at the design flaw and see what he can do. I trust him. He is not just a garage monkey or anything.. he is ASE certified and everything.. I take all my vehciles to him.
Thanks for the info though.

I never heard back from the local pontiac dealer about replacing it for free....

Nevertheless, I still like my 04 GXP

What a trooper! I know how you feel, for the little annoyances they are fantastic cars.

I wonder if someone drilled a hole in the IM assembly, tapped it and added a grease zert, then you could grease it occasionally ~ problem solved. It'* been mentioned here before and something you could ask him about. Just greasing the old one makes it stop clunking. That was the GM fix for quite awhile till they thought a new supplier and design would help. Apparently it didnt.

GM seems to not want to correct it.... just putting a bandage on it.... but I will see how things go with my mechanic... I have not bought the part yet. Have not heard back from my local dealer about replacing the steering shaft for free either... I doubt they get back with me. Money is tight right now, so I am not in a rush just yet... It still drives...lol

Hey Gang.
After lots of research by myself and my mechanic, we have discovered a new design for the steering shaft. The old redesigned one was 10367811...however there is an even newer design that is suppose to not fail like the previous ones.. its number is 26068295.. you can order them online at gmpartsdirect.com or pay 153 bucks at the dealership + labor for them to install it for ya..unless you are under warranty - which I am not..so My mechanic is going to install the newest design in my GXP and I will let you all know how it goes. I just have to pay for the part and he is doing the install for free.

I know this thread is a little older, but some FYI, there are two ways to cure the intermediate shaft "clunking"

1 way is to do the whole GM way which includes ordering a special pin to align the steering wheel straight (for airbag orientation I believe), and removal of steering column, which may also neccessitate disabling and removal of airbag, then steering wheel. There is then a kit (yes, contrary to some poster on the first page, there is a kit), that once the intermediate shaft is out, you bend the U-joint at a 90* angle and spray the contents of the kit into the hole in the u-joint. After which, install a rubber boot cap over that hole and extend contract the intermediate shaft to ensure adequate lubrication. Then reinstall every thing. Trust me, over the years, I've done a fair share of these, it is a b*tch to say the least.

OR, you can do it the CMNT hillrod way which works on our Bonneville'*.

1) Remove the lower kick panel, disconnect the courtesy light electrical connector, move kick panel out of the way

2) Remove the knee bolster. It simply is in place with press-fit clips. Just pull back and it should pop out. This will give you a little more shoulder room while you're down there working.

3) observe a piece of black plastic tubing that runs from the steering column, into a clear'ish rubber boot that is over the intermediate shaft. That clear'ish rubber boot is held in place with a metal ring which has enough flex in it to pull the boot away with your finger.

4) you will see the U-joint. With your finger holding the rubber boot away enough to see the U-Joint, Rotate your steering wheel enough to see clearly the hole in the top of the U-Joint.

5) Grab a can of white lithium grease with one of those long red nozzles on it. With your finger holding the boot open, spray that white lithium grease into that hole in the top of the U-Joint until you see the white lithium grease backing up to the top of the hole.

Since the U-joint is already facing down, gravity will drain the lubricant into the slip joint of the shaft.

6) Put it all back together and enjoy "clunk free" driving of your GXP.

Actually this problem extends to all Bonnveville'*, previous gen STS'*, Impala'*, Monte Carlo'*, Olds Intrigue'*, Pontiac Grand Prix'*, etc...