Topic: 2002-2006 Avalanche Steering - Underhood Clunk Heard/Felt in Steering Wheel TSB

[OH3_Z71]

Bulletin No.: 00-02-35-003N

Date: March 26 2008
Subject:
Clunking Noise Under Hood and Can Be Felt in Steering Wheel and/or Steering Column (Replace Upper Intermediate Steering Shaft [I-Shaft] Assembly)

Models:
2002-2006 Cadillac Escalade Models
1999-2007 Chevrolet Silverado Models (Classic)
2000-2006 Chevrolet Suburban, Tahoe Models
2002-2006 Chevrolet Avalanche
1999-2007 GMC Sierra Models (Classic)
2000-2006 GMC Yukon, Yukon XL Models
2003-2006 HUMMER H2

Attention: This Service Bulletin DOES NOT include Mid-Size Utilities such as Buick Rainier, Chevrolet TrailBlazer Models, GMC Envoy Models or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A or newer for Mid-Size Utilities.

Supercede:

This bulletin is being revised to add diagnostic information (refer to Diagnostic Tips) to check the lower steering column bearing as a potential source of the noise. Please discard Corporate Bulletin Number 00-02-35-003M (Section 02-Steering).

Condition

Some customers may comment on a clunk-type noise coming from under the hood that also can be felt in the steering wheel. These conditions may be more noticeable when turning at low speeds on rough road surfaces.

Diagnostic Tips

Use the information below to help diagnose the source of the noise.
^    The lower steering column bearing may create the same noise as the intermediate shaft. Before replacing the I-shaft, verify the noise isn't being caused by movement from the lower steering column bearing. Check the bearing for movement by pushing up and down on the I-shaft where it attaches to the steering column.

^    Frame Snap and/or Popping Type Noise - A frame snap or popping type noise can be duplicated on rough or smooth road surfaces with steering wheel input to the left or the right. This type of noise can be HEARD and is typically louder with the windows rolled down. For additional information refer to Corporate Bulletin Number 03-08-61-002F or newer - Snap/Popping Type Noise Coming from Front of Vehicle (Remove Front Crossmember Change Fastener Orientation).

^    Intermediate Shaft Clunk - Intermediate shaft clunk is heard and FELT in the steering wheel and/or steering column area typically while driving on rough road surfaces with steering wheel input.

Correction

   Important:
^    I-shaft P/N 19153614 has been designed to replace previous designed dampened and non-dampened I-shafts. The physical difference in the yoke size will accommodate all vehicles listed in this bulletin.

^    Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft.

Replace the steering column upper intermediate shaft with an improved design shaft that will eliminate the clunk noise.

I have heard you can pack the shaft full of grease and this fixes the problem rather then taking it to the dealer and having it repaired. I have also heard and experienced dealers packing it with grease instead of replacing the shaft. If your Avalanche is still under warranty they will fix it. My father had two Avalanche's (03 and 05) both had this problem and the dealer did not replace the shaft, they packed it with grease. My 03 just started the "clunking" noise about a week ago at 95,xxx miles.

[oHIobellboy]

My mechanic told me that you can also disconnect it and "pump" it back and forth about 20 times. Seems all the grease moves to one end during normal use. Have never tried it but it's something to keep in mind.

[bluedevil]

Mine has a clunk for the past 4-5 years.

Im taking obb's advice someday. I'd hate to remove the blower for this. 

[ChevyGuyNC]

Dealer replaced the I-shaft on my '06 two years ago. No noise since.

And no top end removal either BD...

 I think there was a write up over on tos on how to do it yourself. All from inside the cab IIRC. Shaft itself is under $100.


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[oHIobellboy]

Dealer replaced the I-shaft on my '06 two years ago. No noise since.

And no top end removal either BD...

 I think there was a write up over on tos on how to do it yourself. All from inside the cab IIRC. Shaft itself is under $100.


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are you saying to replace it from inside? Or just grease it from inside?

[thomsen05]

From what I have heard the dont sell the packing kits anymore for the ISS but you can pick up a new shaft at summit racing for like 50.00 or 60.00 and they can be replaced by pulling thru the inside of the truck or the outside.
my new dorman shaft has been in my garage for over a year, one of these days i might get to swapping it out.

[oHIobellboy]

I think I've got some pix on here from when I replaced mine. Wasn't too bad of a job. I just moved my seat the whole way forward, ran the seat belt through the steering wheel and clicked it in then moved the seat back to hold the SW steady. You don't want to have to replace the SIR coil.

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[BrentAL]

What is the new part number to order to correct this issue?