Ding! Actually, GM has now notified dealers to try lubing the intermediate shaft first. If after lubing it and the clunking doesn't go away, THEN replace it.

There is a whole process to re-lube it GM's way which includes removal of the steering column (and disabling/removal of the airbag if necessary) and then removal of the intermediate shaft. Then lubing it with a "lube kit", expanding/contract the two halves of the shaft, multiple times, then re-installing it. However, as mentioned above, you can do it this easy way. :D I would recommend something other than chain lube as that may be a little too thick to run all they way down the shaft.

Pull the lower kick panel, push away the clear rubber boot around the bend in the I-shaft, you may have to turn the steering wheel slightly to get the U-joint at the right angle, then using white lithium grease, and the long red nozzle from the can, spray into the hole at the end of the shaft until it starts coming out.

This affects all Bonneville's, Impala's/Monte Carlo's, Grand Prix's, Alero's, Intrigue's, Aurora's, and many other common GM FWD vehicles and as mentioned GM trucks.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

my '05 GXP 38k miles has that click click that I can feel in the steering wheel. I think that is what you all are talking about. I inquired at the dealer and was told the shaft would be about $115 and another hundred for installation. The click is not that bad but it bugging me enough to take it in

_________________
'05 GXP Red 38k miles
'88 SSE Maroon[/img] 170k miles

You can lube, or replace it yourself. It's not a tough job.
http://www.pontiacbonnevilleclub.com/forum/viewtopic.php?f=55&t=217

Spraying some lube in the upper boot area can also work. I've found that plain motor oil works best. I did that on my friend's car, and it would last a bit over a year. Eventually, I did have to take it out and lube it, as that no longer worked.

_________________
*Gone, but not forgotten* - Black 2000 SSEi, HIR Headlights, Angel Eyes fogs, 3rd brake light overlay, hi-flo cat, 180 degree thermostat, HS 1.9 rockers, LSx yellow springs, Intense FWI, PCM, shift kit, push rods, and 3.4 Pulley. ZZP Power Log.

That's a fault of using plain motor oil, It drains/drips away as it runs down the shaft. Use a white lithium grease or something that won't or won't drip away as quickly. The lube GM recommends is similar to a white lithium grease.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

Yup I used chain lube and then a couple months later added some lithium grease.. Hasn't clunked in almost a year now.

That was the first stuff I tried. It didn't do that job in that case. The motor oil did.

_________________
*Gone, but not forgotten* - Black 2000 SSEi, HIR Headlights, Angel Eyes fogs, 3rd brake light overlay, hi-flo cat, 180 degree thermostat, HS 1.9 rockers, LSx yellow springs, Intense FWI, PCM, shift kit, push rods, and 3.4 Pulley. ZZP Power Log.

How much white lithium did you shoot in there? I keep spraying until it's spewing out the top of the U-joint. Let it work it's way down the inside of the slip shaft, then re-spray and repeat until completely full.

Never had any issues and usually saved GM warranty dollars for labor and or shaft replacement.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

Enough that the overflow started to come out by the rack. Lubing the shaft in this manner will work many times, but odds are the eventually, it will have to be pulled. Plus, sometimes, it's the top U-joint that starts to bind and cause the noise. It's easier to work the lube into the joint with the shaft out of the car.

_________________
*Gone, but not forgotten* - Black 2000 SSEi, HIR Headlights, Angel Eyes fogs, 3rd brake light overlay, hi-flo cat, 180 degree thermostat, HS 1.9 rockers, LSx yellow springs, Intense FWI, PCM, shift kit, push rods, and 3.4 Pulley. ZZP Power Log.

Yea, I'm pretty familiar with these, I've replaced a lot of them! I used to work in a Chevy service department ya know. Enough were misdiagnosed and simply replaced, that GM created a TSB to have dealers stop replacing them and having them lube them instead with a service kit. It is bulletin 01-02-32-001C published 9/12/2003, replacing bulletin 01-02-32-001B (section 2, steering)

It covers;
2001-2004 Buick Regal
2000-2004 Cadillac Seville STS
1997-2004 Chevrolet Cavalier
2000-2004 Chevrolet Impala, Monte Carlo
2001-2003 Oldsmobile Aurora
1998-2002 Oldsmobile Intrigue
1997-2004 Pontiac Sunfire
2000-2004 Pontiac Bonneville
2003-2004 Pontiac Grand Prix

It specifically states;


It specifies the lube kit as P/N 26098237, and if done under warranty, it has to be listed as labor operation E7700, using listed publish time plus 0.1/hr additional for lubrication of the shaft. If it gets to the point that you need to replace the shaft because of wear on the pins in the U-joint, you must be running a road course all day, every day at 5mph... Otherwise, simply replacing it doesn't necessarily fix the problem, and you'll just end up needing to lube the new unit anyway.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

Yup, I'm quite familiar with the shaft problems, and know of the TSB, as well as the "new and improved" shaft that went from the splined shaft to the double "D" design. How the U-joint gets to the condition it does at times is hard to say for sure. The fact is, that it does.

_________________
*Gone, but not forgotten* - Black 2000 SSEi, HIR Headlights, Angel Eyes fogs, 3rd brake light overlay, hi-flo cat, 180 degree thermostat, HS 1.9 rockers, LSx yellow springs, Intense FWI, PCM, shift kit, push rods, and 3.4 Pulley. ZZP Power Log.

Had my GXP I-shaft lubed at the dealer. $18 for the lube kit and $95 labor. good now but it's only been a couple of weeks. I'ld like to try it myself next time (and I expect the problem to return) but don't even know how to pull down the boot in the footwell as has been suggested. I'll go out and take a look at it in the morning to see if I can figure out what you are talking about. PS: the dealer would install a new shaft for $350 but it doesn't sound (from you guys) like that will permanently fix the problem. Thanks for your informative postings. //bm

_________________
'05 GXP Red 38k miles
'88 SSE Maroon[/img] 170k miles

The boot? As in the decorative knee bolster? It just slides back as it has pressure fit clamps that snap it into place. You may have to work it out from where it meets with the center console.

The lower panel is removed by undoing the two 5/32's screws, then you can disconnect the footwell courtesy lamp and toss that piece aside.

Once all that is removed, you will see a black plastic tube that feeds into a clear plastic tubing. Where they connect, is where you need to work open. You'll see the u-joint right behind it. That is where we shoot the lubricant into using the hillbilly method. :D

If you want to do the whole shebang, it requires disabling the airbag and steering column removal.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

I am buying a 05 Bonneville GXP with 50,000 mi. Carfax says it has had steering shaft replaced at 13,000 mi and again at 49000 mi with a upgraded shaft. Anyone know the skinny on this issue? Should I stay away from the car?

If there's a reason to stay away from a car, this isn't it. The worst that happens is that it clunks and annoys you, there's been no accidents due to it that we know of.

_________________
Bye Bye:

RIP sandrock

Re-read this whole thread. It'll give you everything you need to know about it. It isn't a safety issue, it won't deteriorate performance, or cause harm. It'll just clunk when turning the wheel around and around at slow speeds.

Like above, this wouldn't be a reason to stay away from this car. The fact that it has been replaced means you probably don't have to deal with the clunking like the rest of us, so that's a good thing and a bonus for you!

78k and still loving/hating this car.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck

I want to bump this thread up to the top as my wife's GXP has this issue and after driving it today I want to get it taken care of. Is GM still replacing this shaft for free? From the discussion it seems like a fairly easy thing to do to lube it yourself. Does anyone have any knowledge on what the dealer's are doing for this? Her car has 56K miles on it.

They only replaced them for free under the 3yr/36k warranty....

_________________
Bye Bye:

RIP sandrock

Doh, didn't realize this was a two pager and I already responded multiple times.

_________________


Retired Bonneville Owner and former GM Tech:
2004 Pontiac Bonneville GXP: Black/Ebony *SOLD*

Summer Toys: Combined 827 RWHP / 877lb/ft RWTQ
2004 Pontiac GTO: Impulse Blue Metallic/Black/M6: lots 'o mods, 415 RWHP / 405lb/ft RWTQ!
2006 Cadillac STS-V: Light Platinum Metallic/Light Gray/A6 - Spectre CAI, Magnaflow exhaust, Speed Inc. tune, 412 RWHP / 472lb/ft RWTQ

Daily Drivers:
2019 Chrysler Pacifica Limited: Mommy's new RGC
2015 Chrysler Town & Country Limited Platinum: Kids new RGC
2007 Chrysler Town & Country Limited: Sold to neighbor
2009 Pontiac G8 GT: L76, Sport Red Metallic
2003 Chevrolet Suburban 2500: Doeskin Tan - 8.1L Big Block... new plow truck
1999 Chevrolet Suburban: Sunset Gold Metallic - Daddy's winter beater and plow truck