Pop, Clunk, Thump or Knock Noise from Front End of Vehicle During Suspension Movement (Adjust Intermediate Shaft Connection at Steering Gear Assembly)

Some customers may comment on a pop, clunk, thump, or knock noise coming from the front end of the vehicle during significant suspension movement.

This condition may be caused by the intermediate shaft contacting the front of dash.

Verify the concern, then adjust the intermediate shaft connection at the steering gear assembly, if necessary. Refer to the service procedure in this bulletin.

1. Verify concern using Chassis Ear (SA9217NE ), or equivalent.
2. Raise and support the vehicle. Refer to "Lifting and Jacking the Vehicle" in the General Information section of the 2004 Saturn VUE Service Manual, Vol. 1 (SI Document ID #995301).

Notice: Lock the steering column to prevent damage and a possible malfunction of the SIR system.

3. With the steering wheel in the straight forward position, remove the ignition key.



4. Remove the intermediate steering shaft to steering gear pinch bolt. Discard the pinch bolt.

Notice: Use the correct fastener in the correct location. Replacement fasteners must be the correct part number for that application. Fasteners requiring replacement or fasteners requiring the use of thread locking compound or sealant are identified in the service procedure. Do not use paints, lubricants, or corrosion inhibitors on fasteners or fastener joint surfaces unless specified. These coatings affect fastener torque and joint clamping force and may damage the fastener. Use the correct tightening sequence and specifications when installing fasteners in order to avoid damage to parts and systems.

5. Install a new lower intermediate shaft pinch bolt finger tight. Do not torque the bolt at this time.
6. With intermediate shaft pinch bolt installed finger tight, push up on the intermediate shaft lower joint so it is in the highest upward position away from the steering gear.
7. Tighten the new lower intermediate shaft pinch bolt while holding upward pressure on the intermediate shaft.

Tighten
Tighten lower intermediate shaft pinch bolt to 34 N·m (25 lb-ft).

8. Lower the vehicle.
9. Verify repair.

To receive credit for this repair during the warranty coverage period, submit a claim through the Saturn Dealer System for E7418 (Shaft, Steering, Intermediate -- Adjust).