TSB #00-02-35-003E - (Jul 20, 2004)

Clunking Noise Under Hood and Can Be Felt In Steering Wheel (Replace Upper Intermediate Steering Shaft Assembly)

2002-2003 Cadillac Escalade, Escalade EXT

2003 Cadillac Escalade ESV

1999-2003 Chevrolet Silverado

2000-2003 Chevrolet Suburban, Tahoe

2002-2003 Chevrolet Avalanche

1999-2003 GMC Sierra

2000-2003 GMC Yukon, Yukon XL

2003 HUMMER H2

with Recirculating Ball-Type Steering

This bulletin is being revised to include the replacement of the intermediate shaft . Please discard Corporate Bulletin Number 00-02-35-003D (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.


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

Set the front wheels in the straight-ahead position.

Notice
On 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 these steering columns. 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 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, do the following steps.
Reposition the carpet away from the accelerator pedal position (APP) sensor.
Remove the two nuts retaining the accelerator pedal to the bulkhead.
Reposition the accelerator pedal out of the way so that 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 shaft.
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. See the parts table below.
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
Tighten the bolt to 47 N·m (35 lb ft).

Install the lower bolt and nut. Tighten
Tighten the bolt to 50 N·m (37 lb ft).

For vehicles equipped with adjustable foot pedals, do the following steps.
Reposition the accelerator pedals into position on the bulkhead.
Install the two retaining nuts. Tighten
Tighten the nuts to 20 N·m (15 lb ft).

Reposition the carpet back into place.
Parts Information
Part Number
Description
Qty

88963611
Shaft, Upper Intermediate Shaft

Use on all 1500 Series trucks:

Except Escalades

Except Denalis

Except Avalanches
1

89060582
Shaft, Upper Intermediate Shaft

Use on all 2500 and 3500 Series Trucks and

Escalades

Denalis

Avalanches

H2
1


Parts are currently available from GMSPO.

Warranty Information
For vehicles repaired under warranty, use:

Labor Operation
Description
Labor Time

E7700
Shaft, Steering Intermediate-Upper - Replace
0.3 hr

Add
For vehicles equipped with adjustable foot pedals
0.1 hr

This TSB replaces the one that recommends greasing the shaft with the plug kit. The latest fix is to replace the intermediate shaft itself with an updated shaft. The grease kit has always been a temporary fix that needed to be repeated every 5k miles or so. The new shaft should be a permanent fix.

Steering - Underhood Clunking Felt in Steering Wheel

Clunking Noise Under Hood and Can Be Felt in the Steering Wheel (Lubricate the Intermediate Steering Shaft Assembly) # 00-02-35-003G - (Oct 22, 2004)

Models:
2002-2003 Cadillac Escalade, Escalade EXT
2003 Cadillac Escalade ESV
1999-2003 Chevrolet Silverado
2000-2003 Chevrolet Suburban, Tahoe
2002-2003 Chevrolet Avalanche
1999-2003 GMC Sierra
2000-2003 GMC Yukon, Yukon XL

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.

This bulletin is being revised to notify dealers that it is acceptable to service the intermediate shaft with Lubrication Kit P/N 26098419 until sufficient inventory of the replacement intermediate shaft part numbers become available from General Motors Service Parts Operations (GMSPO). Please discard Corporate Bulletin Number 00-02-35-003F (Section 02 -- Steering).