donbrew

GM TSB 04-03-08-006E covers ALL of the noises, rattles and etc. from the front end (including EPS and sway bars and struts).

Thanks to badassbowtie the link previously in the spot is not needed.


Thanks to member TVCCS for finding a link to this newer version with pics
GM TSB 04-03-08-006G

http://www.askatech.com/AskATechLive...er.ashx?a=5413

badassbowtie

2010 Chevrolet HHR LT 2010 Chevrolet HHR LT
Steering and Front Suspension Noise Concerns - Clunk, Thump, Rattle, Knocking, Pop, Shudder, Vibration (Diagnosis
and Perform Necessary Repair)

Steering and Front Suspension Noise Concerns -Clunk, Thump, Rattle, Knocking, Pop,
Shudder, Vibration (Diagnosis and Perform Necessary Repair)


TECHNICAL SERVICE BULLETIN


Reference Number(s): 04-03-08-006E, Date of Issue: November 01, 2010
Affected 2005-2010 Chevrolet Cobalt (Including SS); 2006-2010 Chevrolet HHR (Including SS); 2005Model(
s): 2006 Pontiac Pursuit (Canada Only); 2007-2010 Pontiac G5; 2003-2007 Saturn ION

This bulletin is being revised to add 2010 model year and update Condition #7 with new part
information. Please discard Corporate Bulletin Number 04-03-08-006D (Section 03 -

Supercedes:

Suspension). This bulletin provides information on eight different steering/front suspension noise
conditions.
Superceded Bulletin(s): 04-03-08-006D, Date of Issue: February 24, 2009



CONDITION #1

Some customers may comment on a rattle or knocking noise that is heard in the front of the vehicle while
driving at low speeds 8-24 km/h (5-15 mph). This condition may be more noticeable while making a slow turn
or on a loose/rough surface.

This condition can be duplicated by the technician using the following procedure:

1.
On a rough or loose surface (i.e., gravel parking lot), make a sweeping turn (either direction) at 8-24 km/h
(5-15 mph to load the steering column, I-shaft and steering rack/gear mechanisms. The testing on a rough
or loose surface will allow the wheels to oscillate slightly and will make the rattle/knocking noise more
evident and repeatable.
2.
Release the steering wheel while making the turn to take load off of steering components. This should
initiate the rattle/shudder noise, which is generated by backlash in the steering assembly as it is in a no-
load float condition.
Fig. 1: EPS Fuse (1)
Courtesy of GENERAL MOTORS CORP.


3.
Remove the 60 amp EPS fuse (1) in the underhood fuse block.
4.
Test the vehicle as in Step 1. Since the EPS motor is no longer powered, only the I-shaft and steering
gear/rack will be loaded as you make the turn. If you hear the rattle/knocking noise during the turn, then
the noise is being generated by the backlash within the steering column (assist motor gear mechanism).
5.
Replace the 60 amp EPS fuse and repeat Steps 1 and 2 to verify that the rattle/knocking noise disappears
when turning (loading steering mechanism) and can only be heard when releasing the steering wheel.


CORRECTION #1

If the steering column is identified as the source of the rattle/knocking noise in the above test, replace the
steering column.

IMPORTANT: The noise in the steering column is generated from the metal to plastic gear backlash of the assist motor mechanism and will have a different sound than
that from the steering gear. If the customer comments that they still hear a
noise, it may be a different sound from either the I-shaft or the steering rack.

If the steering column is not identified as the source of the rattle/knocking in the above test, continue to
diagnose the vehicle according to the diagnostics in SI.

PARTS INFORMATION #1

For part numbers and usage of the column, see Steering Column Kit in Group 06.518 of the appropriate Parts
Catalog. Saturn Retailers should refer to the appropriate model year Parts & Illustration Catalog for the vehicle.

WARRANTY INFORMATION #1

For vehicles repaired under warranty, use:

Warranty Information #1

Labor Operation Description Labor Time
E7680 Column Assembly, Steering - Replace Use Published Labor
Operation Time




CONDITION #2 (CHEVROLET COBALT, HHR AND PONTIAC G5 ONLY)

Some customers may comment on a clunk or thump noise coming from the front suspension while driving over
rough road surfaces. This noise will typically occur when the front suspension is returning to the upward
position after a hard downward stroke, such as after driving through a large rut or pothole.

CAUSE #2

This condition may be caused by the jounce bumper slamming into the upper spring seat because it is not
retained in the correct up position. The jounce bumper loses position due to oil being deposited onto its
retention fingers. The oil is from the strut leaking.

CORRECTION #2

Inspect the front strut(s) for evidence of oil. The leak may be slight but will still cause the concern. If oil is
present, replace the affected strut, jounce bumper and dust boot (shield). Before reassembling the strut
assembly, glue the new jounce bumper and new dust boot (shield) to the upper spring seat using the steps listed
below. To further confirm this concern, the shield/bumper will easily slide up and down the strut shaft.

Fig. 2: Upper Spring Seat

Courtesy of GENERAL MOTORS CORP.

1. Clean the surface area of the upper spring seat using fine sandpaper.
2. Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot (shield) on the inside edge and to the top of the bumper. Allow to dry 10 minutes.

Fig. 3: Dust Boot (Shield)

Courtesy of GENERAL MOTORS CORP.

3.
Glue the bumper to the inside of the dust boot (shield) as shown. Use *3M™ Duramix™ Super Fast
Adhesive, P/N 04747. Allow to cure thoroughly 5-10 minutes at room temperature.
4.
Apply a light coat of *3M™ Automotive Adhesion Promoter, P/N 06396, to the top of the dust boot
(shield) and to the upper spring seat surface. Allow to dry 10 minutes.
Fig. 4: Dust Boot (Shield) & Upper Spring Seat

Courtesy of GENERAL MOTORS CORP.

5.
Glue the dust boot (shield) to the upper spring seat as shown using the above recommended adhesive.
Allow to cure thoroughly.
*We believe this source and their products to be reliable. There may be additional manufacturers of such
products. General Motors does not endorse, indicate any preference for or assume any responsibility for the
products from this firm or for any such items which may be available from other sources.

PARTS INFORMATION #2

Parts Information #2

Part Number Description Qty Material Allowance
21992520 Shield, Frt Suspension
Strut --
22712118 Bumper, Frt Suspension
Strut --
04747 3M™ Duramix™ Super
Fast Adhesive 1 $22.00
06396 3M™ Automotive
Adhesion Promoter 2 $4.00

For part numbers and usage of the strut, see Strut Kit in Group 07.345 of the appropriate Parts Catalog.

WARRANTY INFORMATION #2

For vehicles repaired under warranty, use:

Warranty Information #2

Labor Operation Description Labor Time
E9478* Replace Front Strut and Secure Bumper and Shield to
Spring Seat 1.5 hrs
Add To Perform Repair on Other Side 1.3 hrs
Add For alignment times, refer to operation E2020 and add the applicable times to
the regular hours.
* This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.



CONDITION #3

Some customers may comment on a clunk/pop type noise coming from the front of the vehicle when driving
over rough road surfaces.

CAUSE #3

This noise may be caused by the stabilizer shaft link ball stud becoming contaminated from moisture.

CORRECTION #3

Inspect the front stabilizer shaft links for damage. To isolate the noise, the link can be also be disconnected
from the stabilizer shaft. If the link appears damaged or if the noise goes away when disconnected, replace the
link with the revised part.

PARTS INFORMATION #3

Parts Information #3

Part Number Description Usage Qty
20784686
Link Asm., Front
Stabilizer Shaft (300 mm
Shaft)
2006-2009 HHR (FE1, FE3)
2005-2009 Cobalt (FE1, FE3)
2005-2006 Pursuit (FE1, FE3)
2007-2009 G5 (FE1, FE3)
2003-2007 ION (FE1, FE2, FE3)
2
20784687
Link Asm., Front
Stabilizer Shaft (250 mm
Shaft w/Washer)
2008-2009 HHR (FE5)
2005-2009 Cobalt (FE5)
2007-2009 G5 (FE5)
2
20784688
Link Asm., Front
Stabilizer Shaft (250 mm
Shaft)
2006-2009 HHR (FE1, FE3)
2005-2009 Cobalt (FE5)
2005-2006 Pursuit (FE5)
2007-2009 G5 (FE5)
2

WARRANTY INFORMATION #3

For vehicles repaired under warranty, use:

Warranty Information #3

Labor Operation Description Labor Time
E2147 Stabilizer Shaft Link Replacement (Both Sides) Use Published Labor
Operation Time

badassbowtie

CONDITION #4

Some customers may comment on a clunk type noise coming from the front of the vehicle during a turning
maneuver. This condition can also be felt through the steering wheel when the vehicle is stationary and the
wheel is rotated from steering stop to steering stop. Typically, the clunk noise will be heard once for every 90°
of steering wheel rotation in either direction. This clunk noise may also be noticed during low speed
acceleration or deceleration, typically in light turns of the steering wheel.

The following are characteristics of this noise:

z
This noise is very random.
z
This noise is independent of the steering wheel angle and independent of the bumpiness of the road.
z
This noise is a low frequency dull one and can be felt in your feet.
z
This noise can normally be heard from the driver seat.
z
This noise can be felt upon touching the steering gear from outside of the vehicle.


NOTE:
You might also notice a slight scrub-type noise when turning the wheel backand forth. This type of noise is considered normal and repairs will not eliminate
it.

CAUSE #4

This condition may be caused by inadequate lubrication of the steering intermediate shaft.

CORRECTION #4

IMPORTANT: DO NOT replace the steering gear or steering column assembly.

Replace the intermediate shaft.

IMPORTANT: If the vehicle has already had a steering intermediate shaft replaced for a
similar noise concern that the dealer duplicated, determine from the customer
if the noise went away for a period of time and came back, or if the service
shaft made no change. If the noise was gone for a period of time and came
back, have the dealer replace the shaft again to verify we do not have a
defective service shaft.

If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.

PARTS INFORMATION #4

Parts Information #4

Part Number Description
15800140 Shaft, Intermediate Steering (Cobalt/G5/Pursuit)


15799676

Shaft, Intermediate Steering (ION)

22730246

Shaft, Intermediate Steering (HHR)

WARRANTY INFORMATION #4

For vehicles repaired under warranty, use:

Warranty Information #4

Labor Operation Description Labor Time
E7700 Shaft, Steering Intermediate - Replace Use Published Labor
Operation Time

CONDITION #5

Some customers may comment on a rattle/clunk type noise coming from the steering column when driving over
bumps.

CORRECTION #5

The following steps have been found to be very effective in removing this condition.

Fig. 5: PCM & TCM

Courtesy of GENERAL MOTORS CORP.

1.
Check for the possibility of the PCM and the TCM rattling/clunking together. If there is contact between
these two modules, insulate the modules from each other using a small piece of foam.
Fig. 6: Retaining Clip

Courtesy of GENERAL MOTORS CORP.

2. Check that the retaining clip on the engine coolant surge tank is fully seated. If not, push down to seat.
Rattles/clunks in this area of the engine compartment may be heard as coming from the steering column while
driving.
If this does not eliminate the noise, continue to diagnose the vehicle according to the diagnostics in SI.


WARRANTY INFORMATION #5

Warranty Information #5

Labor Operation Description Labor Time
E9458* Repair to Correct Rattle/Clunk Noise in Front of
Vehicle 0.2 hr
* This is a unique labor operation for bulletin use only. It will not be published in the Labor Time Guide.



CONDITION #6 (FE1 SUSPENSION ONLY)

Some customers may comment on a clunk, thump or rattle noise coming from the front suspension while
driving over rough road conditions or when braking.

CAUSE #6

Fig. 7: Lower Control Arm Rubber Bushing (Rear)
Courtesy of GENERAL MOTORS CORP.

This condition may be caused by the lower control arm rubber bushing (rear) coming out of its steel sleeve (1).
This will cause the lower control arm to make hard contact (2) with the body structure. This condition may be
more prevalent in regions that use road salt during the winter months.

CORRECTION #6

If the rubber bushing has moved out of the steel sleeve, replace the lower control arm bushing. Do not replace
the bushing if it is still centered in the steel sleeve.

If this does not eliminate the noise, continue to diagnose using chassis ears to identify the source of the noise.

PARTS INFORMATION #6

Parts Information #6

Part Number Description
25984679 Bushing, Front Lower Control Arm (Cobalt/G5/HHR/Pursuit)
22688205 Bushing, Front Lower Control Arm (ION)

WARRANTY INFORMATION #6

For vehicles repaired under warranty, use:

Warranty Information #6

Labor Operation Description Labor Time
E3550 Bushings ad/or Shaft, Front Control Arm Lower (Right)
- Replace
Use Published Labor
Operation TimeE3551 Bushings ad/or Shaft, Front Control Arm Lower (Left) Replace
E3557 Bushings ad/or Shaft, Front Control Arm Lower (Both)
- Replace



CONDITION #7

Some customers may comment on a squeak, rattle, pop, or clunk noise coming from the front of the vehicle during suspension movement.

CAUSE #7 (SATURN ION ONLY)

This condition may be caused by the interface between the front stabilizer shaft, the front stabilizer shaft
insulators (bushings) and the front stabilizer shaft mounting clamp.

CORRECTION #7 (SATURN ION ONLY)

Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure.

1.
Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the
source of the noise. Refer to Noise Diagnosis - Front Suspension in SI.
2.
If the noise is coming from either the front stabilizer shaft insulators (bushings) or the clamps:
z
On vehicles built after VIN breakpoint 4Z125195, replace both front stabilizer shaft insulators
(bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.
z
On vehicles built up to and including VIN 4Z125195, replace the front stabilizer shaft insulators
(bushings) and clamps. Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.

3.
Verify the repair by repeating Step 1.
PARTS INFORMATION #7 (SATURN ION ONLY)

Parts Information #7 (Saturn ION Only)

Part Number Description Qty
15820162 Insulator, Front Stabilizer Shaft (2003-2007 FE1
Suspension) 2
20902787 Insulator, Front Stabilizer Shaft (2003-2007 FE2
Suspension) 2
15820164 Insulator, Front Stabilizer Shaft (2003-2007 FE3
Suspension) 2
22722387 Clamp, Front Stabilizer Shaft 2

CAUSE #7 (COBALT, G5, HHR)

This condition may be caused by the interface between the front stabilizer shaft and the front stabilizer shaft
insulators (bushings).

CORRECTION #7 (COBALT, G5, HHR)

Replace the front stabilizer shaft insulators (bushings), if necessary, using the following procedure.

1.
Verify the customer comment. Use Chassis Ear (SA9217NE or J39570) or a similar tool to determine the
source of the noise. Refer to Noise Diagnosis - Front Suspension in SI.
2.
If the noise is coming from either the front stabilizer shaft insulators (bushings), replace both front stabilizer shaft insulators (bushings). Refer to the Stabilizer Shaft Insulator Replacement procedure in SI.

3. Verify the repair by repeating Step 1.
PARTS INFORMATION #7 (COBALT, G5, HHR)

Parts Information #7 (Cobalt, G5, HHR)

Part Number Description Qty
20902784
(HHR Only)
Insulator, Front Stabilizer Shaft (2006-2010 FE1
Suspension) 2
20902786
(Cobalt, G5)
Insulator, Front Stabilizer Shaft (2005-2010 FE1
Suspension) 2
20902785
(Cobalt, G5)
Insulator, Front Stabilizer Shaft (2005-2010 FE5
Suspension) 2
20902787 Insulator, Front Stabilizer Shaft (2005-2010 FE3
Suspension) 2

WARRANTY INFORMATION #7

For vehicles repaired under warranty, use:

Warranty Information #7

Labor Operation Description Labor Time
E2180 Insulator and/or Bracket, Front Stabilizer Shaft Replace
Use Published Labor
Operation Time

badassbowtie

CONDITION #8

Some customers may comment on a whine/hum noise from the steering column while making right hand turns
at 5-15 mph (8-24 km/h). A slight whine/hum noise is considered to be normal for EPS so it will be helpful to
compare to another like vehicle. If the vehicle exhibits excessive feedback/noise when compared to another
vehicle, follow the correction procedure below.

CORRECTION #8

IMPORTANT: DO NOT replace the steering column.

Fig. 8: 60 Amp Steering Fuse (1)
Courtesy of GENERAL MOTORS CORP.


Pull the 60 amp steering fuse (1) in the underhood fuse block. If this eliminates the whine/hum concern, contact
the Technical Assistance Center for further information in order to repair the vehicle. If this does not eliminate
the noise, continue to diagnose the vehicle according to the diagnostics in SI.

rhondasb1

I had this happen and I've replaced the stabilizing bars and the front struts. None of this has helped this problem.

donbrew

What exactly do you mean by
"this"?

whopper

Love this thread!!!!!

With the number of HHR's on the road starting to hit some significant mileage, does anyone think it might be interesting to put together a poll to try and measure the component failure rate of the various suspension pieces? It might give some insight to the most-common issues (such as the sway bar end links which seem to have a pretty high failure rate to me).

Or perhaps a list of the components x-referenced to the symptoms they cause, with a comment on how to diagnose, similar to the GM info above?

Rotor

I have mostly ignored my clonking noise because it was so random. But it has started to get a bit annoying. I have 167k on my HRR, and love this tank. It is an '06. The clonking started around 75k or so. It doesnt do it while turning, mainly at slow speeds, straight ahead, over the most minute of road imperfections, on and off never consistent. It is not felt in the steering wheel. So, guess i need to go for sway bar bushings and lower control arms?

firemangeorge

At the very least, swaybar bushings and LCA's. With that many miles you should check everything, front and back.
If you haven't done struts and shocks, they ARE worn out.