I brought the car to the shop about 6 months ago, reporting a clunk that can be heard when driving at low speed over bumps. Also, you could replicate the clunk if the wheel was wiggled back and forth, while stopped. Back then, they've acknowledged the problem and replaced the "intermediate steering shaft" under warranty (which fixed the problem nicely).
The exact same clunk appeared a couple of days ago. I brought the car back today, but they refused to admit the problem, saying there's nothing to fix, the steering didn't clunk when they test-drove the car and the clunk when the steering is wiggled is normal and all Cobalts do it. I asked to check a new Cobalt from the lot, but the guy said there's too complicated to get the keys (!?) and even if doesn't do it, that doesn't mean anything, because that's a new car! I started to get annoyed, and I requested a test-drive with a service guy right away. Needless to say, I was able to replicate the clunk in less than 2 minutes. To save their face, they now say it's a totally different problem and the "steering rack" has now to be replaced.
Did anyone else have the same problem? It looks like a design flaw to me...I don't wanna pay for this if it comes back after my warranty is done.

PS I've got a free Cobalt rental, which has the same clunk!!!!!

 

There's a TSB on most GM cars and trucks stating the exact problem you are having. The GM trucks have a new designed steering shaft that HAS to be used to correct the problem. If you use an old number of the shaft you will, over time, get the same noise. I think the same goes with the cobalts. There's a TSB for it also. And the number for the shaft that GM provides as a fix has been replaced by a different number. So it might be just like the trucks.

The TSB is below and the new number is 15800140

Subject: EI05093 - Clunk Noise in Steering System at Slow Speeds While Turning and/or Driving Over Bumps (Replace Intermediate Shaft) #05-02-32-005C - (01/20/2006)



Models: 2005-2006 Chevrolet Cobalt

2006 Chevrolet HHR

2005-2006 Pontiac Pursuit (Canada Only)

2003-2006 Saturn ION




This bulletin is being revised to add additional models and parts information. Please discard Corporate Bulletin Number 05-02-32-005B (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 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 that 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
This condition may be caused by inadequate lubrication of the steering intermediate shaft.

Correction
DO NOT REPLACE THE STEERING GEAR OR STEERING COLUMN ASSEMBLY.

Replace the intermediate shaft.

Parts Information
Part Number
Description
Qty

10394225
Shaft, Intermediate Steering (Cobalt/Pursuit)
1

10392744
Shaft, Intermediate Steering (ION)
1

22730246
Shaft, Intermediate Steering (HHR)
1


Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7700
Shaft, Steering Intermediate - Replace
Use Published Labor Operation Time

 

I brought my car in for the same problem yesterday. I get a call later on and they tell me my struts are broken, my steering shaft is broken, and my doors arent sealed correctly. Hopefully I should have my car back by the afternoon today. Thankfully I still have the warranty and Im hoping everything will be all good. I have a 2005 LS sedan if your wondering.

 

mine is doing the same thing

 

OK, they called me today to pick up my car. After I pay (I also did an annual service) and get my keys, I start driving and surprise, it's clunking even worse!! I go back in and get the mechanic with me for another test drive - he admits the clunking and starts to apolgize for not testing it. After he replaced the steering rack for nothing, he doesn't seem to know what else to do. He wants now to replace the "links" (whatever that is). I told him about the TSB (thanks to fr33k) but he said they already put the updated shaft 6 months ago, when I first brought the car in.
Now I have to wait until they receive the "links", but I suspect those don't have anything to do with it.
I'm starting to get really pissed about the whole thing, not to mention that the car seems to pull to the left now...

 

I've got the same thing in my 05 Pursuit. Waiting on the parts to be ordered. We'll see how it goes...

 

The links is a common thing that goes bad on most cadi's and trailblazers. We haven't had to replace any here on the balts yet. They are the steel rods that connect your sway bar to the strut. It's item number 33 on the pic below that is circled in red.

 

OK, thanks. So, you think replacing the links might fix the clunk?
I don't know much about mechanics, but to me the clunk sounds exactly as it did the first time...I suspect the shaft simply went bad again.

 

Hey marquis I just wanted to give you some news that I don't think you want to hear. I have a 07 cobalt SS SC and my friend has an 06 cobalt SS sedan, and they just finished going through arbitration to get GM to take back there leased SS. The reason for this was months of trying to fix that same clunk in the steering with no sucess, they also had a few other problems but the steering was the one that got them out of their lease. I hate to say it but I think our cobalts are the corvair of our time they are nothing but POS's, the only thing good in these cars is the engine and transmission and surprise surprise the engine was designed by toyota and the ss sc tranny is from saab.

I also want to say dont give up man write GM canada pressure your dealer stay on it . I have been dealing with issues with my car since a week after I got it on NOvember 23, I had a work order opened dec 6 and it was only closed yesterday (March 7), and guess what two of the problems they closed off on are still not fixed.


P.S I could **** in a box and put a five year warranty on it but it is still **** in a box!

 

Thanks for your input. I won't give up, but I'll follow the steps: if the mechanics will say they can't fix it, I'll complain to the service manager and then to GM directly. Hopefully, they'll fix it eventually.

 

its in steering column, plastic gear and bushing broke. i got column off ebay. works great