suspension "squeeking" over bumps

[james11]

Hello,

Happy holidays and wishes for a great season.

My 05 Malibu just got the steering clunk fixed when the cold weather got here and another problem crept up. When I am going slowly over bumps (idle speed to about 10 MPH) there is a squeeking sound a lot like jumping on an old mattress. Believe it or not the sound is worse the less weight I have in the car (for now). The service writer went for a ride in it yesterday, but did not have any idea what the noise was and had no techs to look at it. I have to take it in Monday.

Anyone have any ideas? It's driving me nuts.

James

[coaster.n3rd]

I had the same problem in both my Cobalts.. Do you have the electronic power steering? They replaced part of my steering linkage. I thought it was the suspension.

[james11]

Originally Posted by coaster.n3rd

I had the same problem in both my Cobalts.. Do you have the electronic power steering? They replaced part of my steering linkage. I thought it was the suspension.

Well I've had problems with the steering column so many times I can't count. I know that they havn't replaced the steering linkage yet, but the way things are, I don't think it will be too long before they do. They have replaced the steering gear and the front struts. I do have 65000 on the car though. Warranty to 100000. I'll ask them to check it out. Thank You!!!

[james11]

P.S. I do have the EPS. I thought it was a great thing when I bought it. Now I'm not so sure.

[james11]

If anyone has it, could you post TSB #060232007 . Thanks!!!!!

[coaster.n3rd]

Originally Posted by james11

P.S. I do have the EPS. I thought it was a great thing when I bought it. Now I'm not so sure.

I'm by no means tech savvy. But I notice a lot of the same problems between the two vehicles especially with EPS. Clunking, squeaking, rattles etc etc...

The 4 banger Aura has EPS and it is wonderful. Definitely not the after thought it was on the Malibu, G6, Cobalt/G5 & Ion. Sometimes I feel like I am constantly straightening the car out on long straights and it gets really annoying. Sometimes it does not feel like it tightens up on the turns like it is supposed to.

[GMCSonoma]

Subject:Clunk/Knock/Rattle From Front of Vehicle When Driving/Turning over Bumps (Diagnose Noise - Lubricate Inner/Outer Steering Shaft, Reposition I-Shaft, Add Foam to Radiator Surge Tank Mounting Bracket) #06-02-32-007B - (05/21/2007)

Models:2004-2007 Chevrolet Malibu/Maxx
2005-2007 Pontiac G6
with Electronic Power Steering (EPS)

This bulletin is being revised to update the model years, include more conditions and additional information and update the warranty information. Please discard Corporate Bulletin Number 06-02-32-007A (Section 02 -- Steering).
Condition 1

Some customers may comment on a clunk noise heard and felt in the steering wheel while driving at slow speeds and turning. The clunk noise may appear to be directly in front of the driver. Hitting a bump while turning can produce the clunk noise. Sometimes the noise may be duplicated when the vehicle is sitting still and the steering wheel is turned 90 degrees in either direction before initially centering the steering wheel.
Cause 1

The clunk noise may be caused by the lack of lubrication between the inner and outer steering shafts.
Correction 1

Important: DO NOT disconnect the intermediate shaft to lubricate.
Lubricate the intermediate shaft with GM Superlube using the procedure below:

1. 
   
   <LI type=1>From inside the vehicle, spray GM Superlube, P/N 12346241 (in Canada, use P/N 10953474), into the gap between the inner shaft and outer shaft at the steering shaft for about two to three seconds. <LI type=1>Start the vehicle and turn the steering wheel 180 degrees and spray into the gap between the inner shaft and the outer shaft again for about two to three seconds. <LI type=1>Wipe off any excessive lubricant that may run down the outer shaft with a shop towel. <LI type=1>Cycle the steering wheel lock to lock for two complete cycles. <LI type=1>Verify that the clunk noise is no longer present. <LI type=1>If the clunk noise is still present, raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
2. Check the position of the intermediate shaft as it connects to the steering gear. There may be an interference condition between the clamp and the steering gear input shaft. The clamp is beveled and if forced down on the input shaft too hard, it may cause a loose fit with the intermediate shaft to input shaft joint. To correct this condition, perform the following steps:
   7.1. Loosen the intermediate shaft pinch bolt at the steering gear end.
   
   
   
   
   7.2. Pry the clamp up using a pry bar to position the bolt into the upper part of the groove as shown above. This will position the clamp off of the bevel.
   7.3. While keeping the clamp in the upper position, tighten the bolt.
   Tighten
   Tighten the bolt to 49 N·m(36 lb ft).
   
   7.4. Verify that the clunk noise is no longer present.

">Condition 2

Some customers may comment on a knocking or rattling type noise from the front of the vehicle when driven at low speeds and over bumps. The noise only occurs when the steering wheel is in the straight ahead position and sounds like the noise is in the left suspension of the vehicle or directly in front of the driver.
Correction 2

1. <LI type=1>Determine the source of the noise. Install the chassis ears at the following locations:
   • sway bar link, one side at a time
   • upper strut mount, one side at a time
   • steering gear near the pinion area
   • base of the steering column housing
   • radiator surge tank
   <LI type=1>If the noise is coming from the upper strut mount or sway bar link, replace as necessary and retest. <LI type=1>For 2004-2006 model year vehicles, the noise may be coming from the radiator surge tank area. (The 2007 model year vehicles use a different style radiator surge tank - refer to Step 9.) <LI type=1>If the noise is coming from the radiator surge tank, release the two retaining tabs holding the radiator surge tank and reposition the tank away from the attaching bracket and isolate with closed cell foam. <LI type=1>Cut three pieces of closed cell foam, P/N P46515 (or equivalent), into 25 mm (1 in) by 102 mm (4 in) pieces. <LI type=1>Cut two pieces of closed cell foam into 25 mm (1 in) by 6 mm (¼ in) pieces.
   
   
   <LI type=1>Install the three pieces of foam to the attaching bracket starting at the top center inside the bracket and proceed down across the fuel lines, then at the inside of the bracket at the left and right positions of the center piece of foam. Finally, install the last two pieces of foam to the inside bracket at the left and right extended sides behind the retaining holes as shown above. <LI type=1>Reposition the radiator surge tank back onto the bracket and seat the two retaining tabs on the tank. <LI type=1>Drive the vehicle to verify that the noise is no longer present.
2. If the intermediate shaft position was correct, the I-shaft was lubricated, and the closed cell foam was added to the radiator surge tank bracket for 2004-2006 model year vehicles, then the noise the customer is hearing is from the rack gear and pinion gear contact internally in the steering gear. The steering gear should be replaced with the new part number gear listed below. Refer to the Power Steering Gear (EPS) Replacement procedure in SI.

Parts Information

Order Adhesive Back Shim Stock from Kent Automotive at 1-888-YES-KENT or online at www.kent-automotive.com.
Part Number
Description
Material Allowance
P46515
Adhesive Back Shim Stock (25 mm x 30 ft roll) [15 mm (9/16 in) thickness]
$1.60 per vehicle ($1.78 in Canada)
Part Number
Description
15858368 (Base Gear)
Steering Gear Assembly
15858369 (Restricted Travel Gear) (Vehicles with 17" Wheels)
Steering Gear Assembly

Warranty Information

For vehicles repaired under warranty, use:
Labor Operation
Description
Labor Time
E9448*
Lubricate and Reposition I-Shaft to Correct Noise
0.3 hr
Add
Install Foam (2004-2006)
0.1 hr
* This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.
For other repairs, submit the appropriate published labor operation.

[james11]

Thank you very much Sonoma!!!!!

My neighbor is a tech at a pontiac dealership and he just took the car for a ride. He says that the noise is comming from the underbody of the car and closer to the rear of the vehicle. Possibly a bad strut or a loose connection, but he's not sure. Anyway, the service advisor has heard it, so now at least whan I take it in they can't tell me that they don't hear it. Theres is one good thing. I just need patience now

Happy Holidays

P.S. GM is giving me a covered component letter to warranty the EPS for 100,000 miles due to all the problems I have had with it. THANK YOU GM!!!!! Loyal customer for life!!!!!