Hummer Forums by Elcova - TSB - Clunking Noise Under Hood and Can be Felt in Steering Wheel

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<H1>Clunking Noise Under Hood and Can be Felt in Steering Wheel (Replace Upper
Intermediate Steering Shaft Assembly) #00-02-35-003F -
(08/04/2004)</H1></TABLE>Clunking Noise Under Hood and can be felt in Steering
Wheel (Replace Upper Intermediate Steering Shaft Assembly)

2002-2003 Cadillac Escalade, Escalade EXT</P>

2003 Cadillac Escalade ESV</P>

1999-2003 Chevrolet Silverado</P>

2000-2003 Chevrolet Suburban, Tahoe</P>

2002-2003 Chevrolet Avalanche</P>

1999-2003 GMC Sierra</P>

2000-2003 GMC Yukon, YukonXL</P>

2003 HUMMER H2</P>

(Affected vehicles include both 2WD and 4WD vehicles).</P>

This Service Bulletin DOES NOT include Mid-Size Utilities such as
Buick Rainier, Chevrolet TrailBlazer / TrailBlazer EXT, GMC Envoy / Envoy XL /
Envoy XUV or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A for
Mid-Size Utilities.</P>

This bulletin is being revised to include two-wheel drive vehicles and
clarify vehicle usage. Please discard Corporate Bulletin
Number00-02-35-003E (Section02 -- Steering).</P><A
name=ss1-1542538><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1542538&pubid=293&evc=sm#ss1-1542538">
<H5>Condition</A></H5>

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.</P><A
name=ss2-1542538><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1542538&pubid=293&evc=sm#ss2-1542538">
<H5>Correction</A></H5>

Replace the steering column upper intermediate shaft with an improved design
shaft that will eliminate the clunk noise using the procedure listed below.</P>

<LI type=1>Set the front wheels in the straight-ahead position.

<FONT color=blue>
<H4>Notice</H4>

On 2002 and later model year vehicles, the steering column LOCK was removed
from the steering column. It is critical that the J42640 Steering Column
Anti-Rotation Pin is used when servicing these steering columns. Failure to
use the J42640 may result in damage to the SIR coil.</P></FONT>

</P>
<LI type=1>Set the steering wheel in the LOCK position on 2001 and prior
vehicles.

<LI type=1>Install the J42640 in the steering column lower access hole.

<LI type=1>From under the hood, remove the lower bolt that connects the upper
intermediate shaft to the steering gear coupling shaft.
<LI type=1>Slide the shaft towards the dash in order to disengage the shaft
from the steering gear coupling shaft.
<LI type=1>For vehicles equipped with adjustable foot pedals, do the following
steps.
<UL type=BULLET>
<LI>Reposition the carpet away from the accelerator pedal position (APP)
sensor.
<LI>Remove the two nuts retaining the accelerator pedal to the bulkhead.
<LI>Reposition the accelerator pedal out of the way so that the intermediate
shaft can be removed. </LI>

<LI type=1>From inside the vehicle, remove the upper bolt from the upper
intermediate steering shaft(1) to the steering column connection.
<LI type=1>Remove the upper intermediate steering shaft assembly.
<UL type=BULLET>
<LI>From inside the vehicle, slide the shaft down and off the steering
column shaft.
<LI>From inside the vehicle, slide the upper intermediate shaft through the
dash boot seal and remove the shaft from the vehicle. </LI>[/list] <LI type=1>Replace the upper intermediate shaft. See the parts table below.
<LI type=1>Install the upper intermediate steering shaft through the dash boot
seal and slide the lower end into the steering gear coupling shaft.
<LI type=1>Raise the upper end of the intermediate steering shaft and install
into the steering column shaft.
<LI type=1>Install the upper bolt and nut. Tighten

Tighten the bolt to 47N·m (35lbft).</P>
<LI type=1>Install the lower bolt and nut. Tighten

Tighten the bolt to 50N·m (37lbft).</P>
<LI type=1>For vehicles equipped with adjustable foot pedals, do the following
steps.
<UL type=BULLET>
<LI>Reposition the accelerator pedals into position on the bulkhead.
<LI>Install the two retaining nuts. Tighten

Tighten the nuts to 20N·m (15lbft).</P>
<LI>Reposition the carpet back into place. </LI>[/list]</LI>[/list]<A
name=ss3-1542538></a>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Part Number</P></TH>
<TH vAlign=bottom align=middle>

Description</P></TH>
<TH vAlign=bottom align=middle>

Qty</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

88963611</P></TD>
<TD vAlign=center align=middle>

Shaft, Upper Intermediate Shaft</P>

Use on all 1500 Series trucks:</P>

Except Escalades</P>

Except Denalis</P>

Except Avalanches</P></TD>
<TD vAlign=center align=middle>

1</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

89060582</P></TD>
<TD vAlign=center align=middle>

Shaft, Upper Intermediate Shaft</P>

Use on all 2500 and 3500 Series Trucks and </P>

Escalades</P>

Denalis</P>

Avalanches</P>

H2</P></TD>
<TD vAlign=center align=middle>

1</P></TD></TR></TBODY></TABLE>

Parts are currently available from GMSPO.</P><A name=ss4-1542538></a>

For vehicles repaired under warranty, use:</P>
<TABLE width="100%" border=1>
<TBODY>
<TR>
<TH vAlign=bottom align=middle>

Labor Operation</P></TH>
<TH vAlign=bottom align=middle>

Description</P></TH>
<TH vAlign=bottom align=middle>

Labor Time</P></TH></TR>
<TR>
<TD vAlign=center align=middle>

E7700</P></TD>
<TD vAlign=center align=middle>

Shaft, Steering Intermediate-Upper - Replace</P></TD>
<TD vAlign=center align=middle>

0.3hr</P></TD></TR>
<TR>
<TD vAlign=center align=middle>

Add</P></TD>
<TD vAlign=center align=middle>

For vehicles equipped with adjustable foot pedals</P></TD>
<TD vAlign=center align=middle>

0.1hr</P></TD></TR></TBODY></TABLE>

</P>
<TABLE width="100%">
<TBODY>
<TR>
<TD align=left width=778><FONT size=1>GM bulletins are intended for use by
professional technicians, NOT a "do-it-yourselfer". They are written
to inform these technicians of conditions that may occur on some vehicles,
or to provide information that could assist in the proper service of a
vehicle. Properly trained technicians have the equipment, tools,
safety instructions, and know-how to do a job properly and safely.
If a condition is described, DO NOT assume that the bulletin applies to
your vehicle, or that your vehicle will have that condition. See
your GM dealer for information on whether your vehicle may benefit from
the information.
</FONT></TD>
<TD align=middle width=42></TD>
<TD align=middle width=167><FONT size=2>WE SUPPORT VOLUNTARY TECHNICIAN
CERTIFICATION
</FONT></TD></TR></TBODY></TABLE>
<P align=center>© Copyright General Motors Corporation. All Rights
Reserved. </P>
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<LI type=1>Set the front wheels in the straight-ahead position.

<FONT color=blue>
<H4>Notice</H4>

On 2002 and later model year vehicles, the steering column LOCK was removed
from the steering column. It is critical that the J42640 Steering Column
Anti-Rotation Pin is used when servicing these steering columns. Failure to
use the J42640 may result in damage to the SIR coil.</P></FONT>

</P>
<LI type=1>Set the steering wheel in the LOCK position on 2001 and prior
vehicles.

<LI type=1>Install the J42640 in the steering column lower access hole.

<LI type=1>From under the hood, remove the lower bolt that connects the upper
intermediate shaft to the steering gear coupling shaft.
<LI type=1>Slide the shaft towards the dash in order to disengage the shaft
from the steering gear coupling shaft.
<LI type=1>For vehicles equipped with adjustable foot pedals, do the following
steps.
<UL type=BULLET>
<LI>Reposition the carpet away from the accelerator pedal position (APP)
sensor.
<LI>Remove the two nuts retaining the accelerator pedal to the bulkhead.
<LI>Reposition the accelerator pedal out of the way so that the intermediate
shaft can be removed. </LI>

<!DOCTYPE HTML PUBLIC "-//W3C//DTD HTML 4.0 Transitional//EN">

<HTML><HEAD><TITLE>Service Information</TITLE>
<META http-equiv=Content-Type content="text/html; charset=iso-8859-1">
<META content="Microsoft FrontPage 5.0" name=GENERATOR></HEAD>
<BODY bgColor=#ffffff>
<FORM name=topNavForm action=/servlets/CellHandler>
<TABLE width="100%" align=center>
<TBODY>
<TR>
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<TD align=middle width="50%">Document ID# 1542538 </TD>
<TD align=right width="25%"></TD></TR></TBODY></TABLE>
<HR>
</FORM>
<H1>Clunking Noise Under Hood and Can be Felt in Steering Wheel (Replace Upper
Intermediate Steering Shaft Assembly) #00-02-35-003F -
(08/04/2004)</H1></TABLE>Clunking Noise Under Hood and can be felt in Steering
Wheel (Replace Upper Intermediate Steering Shaft Assembly)

2002-2003 Cadillac Escalade, Escalade EXT</P>

2003 Cadillac Escalade ESV</P>

1999-2003 Chevrolet Silverado</P>

2000-2003 Chevrolet Suburban, Tahoe</P>

2002-2003 Chevrolet Avalanche</P>

1999-2003 GMC Sierra</P>

2000-2003 GMC Yukon, YukonXL</P>

2003 HUMMER H2</P>

(Affected vehicles include both 2WD and 4WD vehicles).</P>

This Service Bulletin DOES NOT include Mid-Size Utilities such as
Buick Rainier, Chevrolet TrailBlazer / TrailBlazer EXT, GMC Envoy / Envoy XL /
Envoy XUV or Oldsmobile Bravada. Refer to Service Bulletin 02-02-35-006A for
Mid-Size Utilities.</P>

This bulletin is being revised to include two-wheel drive vehicles and
clarify vehicle usage. Please discard Corporate Bulletin
Number00-02-35-003E (Section02 -- Steering).</P><A
name=ss1-1542538><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1542538&pubid=293&evc= sm#ss1-1542538">
<H5>Condition</A></H5>

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.</P><A
name=ss2-1542538><A
href="http://127.0.0.1:9001/servlets/BlobShtml?ShtmlFile=1542538&pubid=293&evc= sm#ss2-1542538">
<H5>Correction</A></H5>

Replace the steering column upper intermediate shaft with an improved design
shaft that will eliminate the clunk noise using the procedure listed below.</P>

<LI type=1>Set the front wheels in the straight-ahead position.

<FONT color=blue>
<H4>Notice</H4>

On 2002 and later model year vehicles, the steering column LOCK was removed
from the steering column. It is critical that the J42640 Steering Column
Anti-Rotation Pin is used when servicing these steering columns. Failure to
use the J42640 may result in damage to the SIR coil.</P></FONT>

</P>
<LI type=1>Set the steering wheel in the LOCK position on 2001 and prior
vehicles.

<LI type=1>Install the J42640 in the steering column lower access hole.

<LI type=1>From under the hood, remove the lower bolt that connects the upper
intermediate shaft to the steering gear coupling shaft.
<LI type=1>Slide the shaft towards the dash in order to disengage the shaft
from the steering gear coupling shaft.
<LI type=1>For vehicles equipped with adjustable foot pedals, do the following
steps.
<UL type=BULLET>
<LI>Reposition the carpet away from the accelerator pedal position (APP)
sensor.
<LI>Remove the two nuts retaining the accelerator pedal to the bulkhead.
<LI>Reposition the accelerator pedal out of the way so that the intermediate
shaft can be removed. </LI>