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Hi, new to the forum and in need of some assistance.

I have been chasing a clunk noise on the front of my 07 Cobalt ss/sc i have went through and replaced the majority of the parts in the front end, so control arm and sway bar bushings, tierods, struts, sway bar links and the clunk is still there. I finally got underneath and had somebody shimmy the steering wheel while i felt the intermediate shaft, and i found play in the shaft and the u-joint, making me lead to the fact the shaft is bad. Now i know there is a TSB about the shaft and how it was improperly lubed from the factory as well as other TSB's related to a clunk in the steering relating to the intermediate shaft and/or the steering column. I know GM has released a revised intermediate shaft but now being a student i am very short on cash and have poured all my money into chasing this clunk and cant afford to do any more major work. So i called the customer support center and was told because it is not under special coverage that i am on the hook for any costs related to it. I do not think this is very fair for a problem that lots of people have had and is a serious flaw that even required an updated part. Me and my family have been very longstanding GM only customers and have even been employees at GM dating all the way back to the 30's and would really just like some help in fixing a problem that should be addressed especially after i have spent so much money already trying to fix it and literally cannot afford any other work.
 

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Or you can do what I do on my '01 Monte Carlo when the clunk came back long after it was out of warranty, I just ignore it. Or you can take it loose at one end and stroke it in and out to the limits to redistribute the grease. But it WILL come back eventually. Best learn to live with it now. There have been a half dozen new part numbers on those and eventually they all clunk. Special grease kit wasn't a permanent fix either.
 

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I think he means on the intermediate shaft. We got a couple like that back in the warranty parts bins, I think mostly from pickups since those guys tended to be more McGuiver than car guys. In addition the shaft was easier to R&R on pickups. I'm also guessing that it wasn't totally successful since we were putting on the latest part number after our service manager had agreed to goodwill it. We did a lot of that back then. I'll bet there were more than a few piles of grease on the floorboards of those vehicles.
 
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