2004
Chevy Silverado® Making Clunking Noises
Eric Seifert, Automotive Technical
Editor
Bill’s 2004 Chevy Silverado ® made an odd clunking
noise on the freeway when he ran over those little reflectors while
changing lanes. He could hear and feel the “clunk” in the steering
wheel.
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 surfaces.
Use the information below to help diagnose the
source of the noise.
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. To eliminate the clunk, replace
the steering column upper intermediate shaft with an improved design
(GM ® P/N 19153614) using the procedure below.
Do NOT lubricate or exercise the I-Shaft. 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 procedure. Due to the
design of the new I-Shaft, it is not possible to lubricate/grease
the I-Shaft.
The new intermediate shaft along with GM tool
J 42640 - Steering Column Anti-Rotation Pin (for newer models) will
be required to complete the procedure.
Applicable Vehicles:
2002-2006 Cadillac Escalade Models
1999-2007 Chevrolet Silverado Models (Classic)
2000-2006 Chevrolet SuburbanTahoe Models
2002-2006 Chevrolet Avalanche
1999-2007 GMC Sierra Models (Classic)
2000-2006 GMC Yukon Yukon XL ® Models
2003-2006 HUMMER H2
Attention:
This Procedure DOES NOT include Mid-Size Utilities such as Buick
Rainier, Chevrolet TrailBlazer, GMC Envoy or Oldsmobile Bravada
models.
 Repair
Procedure:
Review safety procedures in ALLDATA ® Repair SM before beginning.
- Set the front wheels in the straight ahead
position.
- On the 2002 and later model-year vehicles,
the steering column LOCK was removed from the steering column.
It is critical that the J 42640 - Steering Column Anti-Rotation
Pin is used when servicing steering columns on 2002 and later
vehicles. Failure to use the J 42640 may result
in damage to the SIR coil.
- Set the steering wheel in the LOCK position
on 2001 and prior model year vehicles.
- For 2002 and newer vehicles, install the
J 42640 in the steering column lower access hole.
- From under the hood, remove the lower bolt
that connects the upper intermediate shaft to the steering gear
coupling shaft. Slide the shaft towards the dash in order to disengage
the shaft from the steering gear coupling shaft.
For vehicles equipped with adjustable foot pedals, perform the
following steps:
• Reposition the carpet away
from the accelerator pedal position (APP) sensor.
• Figure 1 Remove the two
nuts retaining the accelerator pedal to the bulkhead.
• Reposition the accelerator
pedal out of the way so the intermediate shaft can be removed.
- From inside the vehicle, remove the upper
bolt from the upper intermediate steering shaft (1) to the steering
column connection. Remove the upper intermediate steering shaft
assembly.
- From inside the vehicle, slide the shaft
down and off the
steering column.
From inside the vehicle, slide the upper intermediate shaft through
the dash boot seal and remove the shaft from the vehicle.
- Replace the upper intermediate shaft.
- Install the upper intermediate steering shaft
through the dash boot seal and slide the lower end into the steering
gear coupling shaft.
- Raise the upper end of the intermediate steering
shaft and install into the steering column shaft.
- Install the upper bolt and nut. Tighten the
bolt to 47 N.m (35 lb ft).
- Install the lower bolt and nut. Tighten the
bolt to 50 N.m (37 lb ft).
- For vehicles equipped with adjustable foot
pedals, perform the following steps:
• Reposition the accelerator
pedals into position on the bulkhead.
• Install the two retaining
nuts. Tighten the nuts to 20 N.m (15 lb ft).
- Reposition the carpet into place.
Written by ALLDATA Technical Editor, Eric Seifert.
Eric is an ASE certified Master Technician and Engine Machinist.
He is a graduate of the De Anza College Automotive Technology Program,
with 20 years of independent shop and parts store experience.
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