This article recently appeared in the Trentonian Times (trenton, nj paper).

GM SUES PARTS MAKER FOR TOO MANY 'CLUNKS'

General Motors has sued a supplier, saying it has spent more than 30 million fixing problems in the steering systems of the Chevrolet Cobalt, its best selling small car, and other vehicles.
GM said customers have complained about unusual rattles, 'clunks' and other noises. It blamed the flaw on "excessive gear backlash", which causes problems in the steering column when driving on rough roads.

I shared this article with my local chevy service manager after getting a phone call from him saying that GM "approved" the fix on my ss/tc's steering system which makes all sorts of rattles and clunks. first he replaced an intermediate steering shaft, but noise still there!! now waiting for the column to arrive in parts.

 

The shitty thing is the fix is to replace with the exact same part and the problem returns to most cars mine started clunking when my warrenty expired and they wont touch it with out me paying!
mines an 05 LSJ tho so dont feel bad every Cobalt can have this problem

 

dunno why you posted this in lnf... i'm lsj but my car is a "clunker" lol

 

Yes its happening on many models for a long time. My moms Malibu has the issue and it only is a 05 with 52k miles. Ive heard even new malibu's with 10k miles on them get this clunk.

 

I put this in lnf because thats what i drive and this is some major news for those of us that get a hard time from chevy with our fix requests, and this may lead to a recall that will put in a new brand of steering column.... maybe, know I'm being optimistic, but this article sounds pretty serious..... either way I took it in a positive manner

 

My LNF has the clunk and only has 4500 miles on it.

 

Same here..... I have an intermediate shaft on order.

 

What clunk are you talking about? When does it happen?

 

my old dealer told me it was my tire rubbin. lol . thats when i had stock tires . idiots.

 

if its the same clunk im think it happens to me when i turn my wheel like driving kinda slow..its only in certain parts of the turning of the wheel..is this what you guys are talkin about?

 

My clunk is getting fixed next monday Along with my rear calipers, pads and rotors, along with my strap and tensioner assembly...



Only 15 000km on the car (SS/TC 2009) ! At least the car is fun when it's working well!

 

i have all the NHTSA case numbers regarding the steering column **** but i would love to have a link to this article for when i bring my car in in two weeks. anyway you could find a link for this and send it to me. bergen county dealershits are notorious for being dicks when it comes to warranty work.

thanks man for any help

nvm OP i found it. thanks for bringing this to my attention though. i never knew there was an actual lawsuit against the supplier. good job digging up more dirt for my new steering components!

 

Damn to bad my warranty is up

 

I had mine replaced at 6k...the new one started clunking at 6,500

I've been too lazy to get a new one again because it will probably start clunking right away.

 

Is it clunking while you turn or what?

 

Drive straight and over some rough, rippled pavement. If you hear rattling then the column needs to be replaced. If you don't hear it then you'll be ok for a while but it will happen eventually.

 

I guess I'm lucky, 25k miles and no steering clunk. I did have my sway bar end links go all shitty on me though and that caused rattles over uneven pavement, Detroit roads destroy suspension components quickly.

 

Could you please post up a link to this article. No problems with the Steering Rack now (knock on wood) but it would be nice to have this on file just in case.

 

I had a stack of RO's for my 06 cobalt SS that was "fixed" I dont know how many times....now my 08 HHR SS is doing the same damn thing you think GM should have done some thing sooner.

 

mine rattles like a ****, just turn up the stereo, because there is no real fix

 

damnit my intermediate column went to **** and got replaced but i think its doing it again its been 20k though

 

I used to get the clunk all the time.. Slow speeds straight and turning. It was loud as hell, people thought something was wrong with my car. Could be heard out side of it as well. Slow speed and bumps were bad, living in WNY made it especially worse (road suck). I forget exactly what was replaced but it was at least 4-5 things. This happened @ 27k miles, Im at 42 now still going strong...hope it lasts lol.

 

yup i have the same problem, its ******* anoying as hell and i have 83,xxx on mine and its been doing this since atleast 50,000 if not before that. whats the average cost for it to get done?

 

if you all want to see the article just go to google and type words "gm sues parts manufacturer for 30 million" and the article will come up , whether in the trentonian or in some other newspaper, I know it made many different publishers. btw, they replaced intermediate shaft and still made noise, they go cheap first then the expensive column if its still there, and also, sometimes they just grease the shaft. bring that article with you to service and watchg the look on the face of a service advisor, its priceless

 

The longest TSB I have ever seen is about this issue lol

Service Information
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2009 Chevrolet Cobalt | Cobalt, G5 (VIN A) Service Manual | Document ID: 2239750
#04-03-08-006D: Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repairs) - (Feb 24, 2009)

Subject: Steering and Front Suspension Noise Concerns -- Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis and Perform Necessary Repair)

Models: 2005-2009 Chevrolet Cobalt (Including SS)
2006-2009 Chevrolet HHR (Including SS)
2005-2006 Pontiac Pursuit (Canada Only)
2007-2009 Pontiac G5
2003-2007 Saturn ION

This bulletin is being revised to add Condition #3. Please discard Corporate Bulletin Number 04-03-08-006C (Section 03 - Suspension).

This bulletin provides information on seven different steering/front suspension noise conditions.


Condition #1

Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn or on a loose/rough surface.

This condition can be duplicated by the technician using the following procedure:

1. On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h (5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more evident and repeatable.
2. Release the steering wheel while making the turn to take load off of steering components. This should initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-load float condition.

Object Number: 1858410 Size: SH
Click here for detailed picture of above image.
3. Remove the 60 amp EPS fuse (1) in the underhood fuse block.
4. Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then the noise is being generated by the backlash within the steering column (assist motor gear mechanism).
5. Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears when turning (loading steering mechanism) and can only be heard when releasing the steering wheel.

Correction #1

If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the steering column.

Important: The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than that from the steering gear. If the customer comments that they still hear a noise, it may be a different sound from either the I-shaft or the steering rack.

If the steering column is not identified as the source of the rattle/knocking in the above test, continue to diagnose the vehicle according to the diagnostics in SI.
Parts Information #1

For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle.
Warranty Information #1

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E7680
Column Assembly, Steering - Replace
Use Published Labor Operation Time


Condition #2 (Chevrolet Cobalt, HHR and Pontiac G5 Only)

Some customers may comment on a clunk or thump noise coming from the front suspension while driving over rough road surfaces. This noise will typically occur when the front suspension is returning to the upward position after a hard downward stroke, such as after driving through a large rut or pothole.
Cause #2

This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its retention fingers. The oil is from the strut leaking.
Correction #2

Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft.

Object Number: 2159615 Size: SH
Click here for detailed picture of above image.
1. Clean the surface area of the upper spring seat using fine sandpaper.
2. Apply a light coat *of 3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes.

Object Number: 2159607 Size: SH
Click here for detailed picture of above image.
3. Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M™ Duramix™ Super Fast Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature.
4. Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) and to the upper spring seat surface. Allow to dry 10 minutes.

Object Number: 2159612 Size: SH
Click here for detailed picture of above image.
5. Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive. Allow to cure thoroughly.

*We believe this source and their products to be reliable. There may be additional manufacturers of such products. General Motors does not endorse, indicate any preference for or assume any responsibility for the products from this firm or for any such items which may be available from other sources.

Parts Information #2
Part Number
Description
Qty
Material Allowance
21992520
hield, Frt Suspension Strut
22712118
Bumper, Frt Suspension Strut
04747
3M™ Duramix™ Super Fast Adhesive
1
$22.00
06396
3M™ Automotive Adhesion Promoter
2
$4.00

For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog.

Warranty Information #2

For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time
E9478*

Replace Front Strut and Secure Bumper and Shield to Spring Seat
1.5 hrs
AddTo Perform Repair on Other Side

1.3 hrs

AddFor alignment times, refer to operation E2020 and add the applicable times to the regular hours.

* This is a unique labor operation for bulletin use only. The number will not be published in the Labor Time Guide.


Condition #3

Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving over rough road surfaces.
Cause #3

This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture.
Correction #3

Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the link with the revised part.
Parts Information #3

Part Number
Description
Usage
Qty
20784686
Link Asm., Front Stabilizer Shaft (300 mm Shaft)

2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE1, FE3)

2005-2006 Pursuit (FE1, FE3)

2007-2009 G5 (FE1, FE3)

2003-2007 ION (FE1, FE2, FE3)


2

20784687
Link Asm., Front Stabilizer Shaft (250 mm Shaft w/Washer)
2008-2009 HHR (FE5)
2005-2009 Cobalt (FE5)
2007-2009 G5 (FE5)

2

20784688
Link Asm., Front Stabilizer Shaft (250 mm Shaft)

2006-2009 HHR (FE1, FE3)

2005-2009 Cobalt (FE5)

2005-2006 Pursuit (FE5)

2007-2009 G5 (FE5)


2
Warranty Information #3

For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time
E2147
Stabilizer Shaft Link Replacement (Both Sides)

Use Published Labor Operation Time


Condition #4

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: 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 #4

This condition may be caused by inadequate lubrication of the steering intermediate shaft.
Correction #4

Important: DO NOT replace the steering gear or steering column assembly.

Replace the intermediate shaft.

Important: If the vehicle has already had a steering intermediate shaft replaced for a similar noise concern that the dealer duplicated, determine from the customer if the noise went away for a period of time and came back, or if the service shaft made no change. If the noise was gone for a period of time and came back, have the dealer replace the shaft again to verify we do not have a defective service shaft.

If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.
Parts Information #4

Part Number
Description
15800140
Shaft, Intermediate Steering (Cobalt/G5/Pursuit)
15799676

Shaft, Intermediate Steering (ION)
22730246

Shaft, Intermediate Steering (HHR)

Warranty Information #4
For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E7700

Shaft, Steering Intermediate - Replace
Use Published Labor Operation Time


Condition #5

Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over bumps.
Correction #5

The following steps have been found to be very effective in removing this condition.


Object Number: 2003905 Size: SH
Click here for detailed picture of above image.
1. Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between these two modules, insulate the modules from each other using a small piece of foam.

Object Number: 2003906 Size: SH
Click here for detailed picture of above image.
2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat.

Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while driving.

If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.
Warranty Information #5
Labor Operation
Description
Labor Time
E9458*
Repair to Correct Rattle/Clunk Noise in Front of Vehicle
0.2 hr

* This is a unique labor operation number for bulletin use only. The number will not be published in the Labor Time Guide.



Condition #6 (FE1 Suspension Only)


Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while driving over rough road conditions or when braking.
Cause #6

Object Number: 2003907 Size: SH
Click here for detailed picture of above image.

This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1). This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be more prevalent in regions that use road salt during the winter months.
Correction #6

If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace the bushing if it is still centered in the steel sleeve.

If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise.

Parts Information #6
Part Number
Description
25984679
Bushing, Front Lower Control Arm (Cobalt/G5/HHR/Pursuit)

22688205
Bushing, Front Lower Control Arm (ION)
Warranty Information #6

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E3550

Bushings ad/or Shaft, Front Control Arm Lower (Right) - Replace
Use Published Labor Operation Time
E3551
Bushings ad/or Shaft, Front Control Arm Lower (Left) - Replace
E3557
Bushings ad/or Shaft, Front Control Arm Lower (Both) - Replace


Condition #7 (Saturn ION Only)

Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement.
Cause #7

This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft insulators (bushings) and the front stabilizer shaft mounting clamp.
Correction #7

Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure.

1. Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the source of the noise. Refer to Noise Diagnosis - Front Suspension in SI.
2. If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps:

Important: Check the Service Parts Identification label in the rear compartment (trunk) to determine the vehicle's suspension system type, then obtain the correct insulators (bushings) corresponding to that suspension system type.
• On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.
• On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators (bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.
3. Verify the repair by repeating Step 1.

Parts Information #7
Part Number
Description
Qty

15820162
Insulator, Front Stabilizer Shaft (2007 FE1 Suspension)
2

15820163
Insulator, Front Stabilizer Shaft (2007 FE2 Suspension)

2
15820164
Insulator, Front Stabilizer Shaft (2003-2007 FE3 Suspension)

2
22722387
Clamp, Front Stabilizer Shaft
2

Warranty Information #7

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E2180
Insulator and/or Bracket, Front Stabilizer Shaft - Replace
Use Published Labor Operation Time


Condition #8

Some customers may comment on a whine/hum noise from the steering column while making right hand turns at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another vehicle, follow the correction procedure below.
Correction #8

Important: DO NOT replace the steering column.

Object Number: 1858410 Size: SH
Click here for detailed picture of above image.

Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.

GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the equipment, tools, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to your vehicle, or that your vehicle will have that condition. See your GM dealer for information on whether your vehicle may benefit from the information.


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