I think I found the cause of the main rattle. I checked everything again including everybody's suggestions, all seamed to be okay. I checked the steering like you would an old school rear wheel drive car by suspending the car an moving the front wheels. There was a light clunk when the tires were moved front to back and some play. Checking my HHR the same way there was no sound or movement. So my wife ordered a new Delco rack. I will keep you posted. It should be here next week.

 

The input shaft into the steering rack can wear and loosen up, it caused a clunk and shake in my 2007 LS .
Be prepared to replace the intermediate shaft, the lower yoke gets worn out as it can’t be greased.

 

I will check the intermediate shaft more closely when I get the rack out. It was tight and didn't show any movement.
Thanks

 

Here is my how to, from my 2007 LS

https://www.chevyhhr.net/forums/how-...ng-rack-58948/

 

The rattle didn't go after I replace the worn motor and trans mounts. So I retorqued all the suspension bolts and the front end and the rattle was gone. I also have a steering column rattle I think is coming from the air bag mount.

 

I don't know how the airbag mount could rattle unless the airbag is hanging loose and that could be deadly.

 

I will pull it apart and check it. I can't think of anything else that has weight that would rattle in the steering wheel area.

 

I checked the air bag, all is good. I removed the fuze first pulled the air bag and drove around. I felt the column when the rattle was happening. I could feel the vibration getting stronger as I worked down the column. I replaced the column with a used unit from the local LKQ thinking thee was a bad bearing or bushing in the column. Drove it again with all the trim and air bag out, still rattles.I replaced the intermediate shaft with the one I got with the column. When I bumped the shaft before I tightened the lower bolt I heard the rattle. I tightened the lower bolt and got a 80% improvement but not gone. Is the lower coupling a wear item and the problem with intermediate shaft?

 

Read Oldblues post #12.

 

I replaced the rack in November with a Delco unit. It didn't change the rattle when I changed it.