Steering - Steering Column Knocking Noise

No.: LTB00097

Issue: 3

Date: 05 May 2008

THIS BULLETIN SUPERCEDES LTB00097 ISSUE 2, DATED 12 DEC 2007. THE CHANGES ARE SHOWN WITH ASTERISKS.

SECTION: 211-04

Steering Column Knock - Repair Procedure





AFFECTED VEHICLE RANGE

CONDITION SUMMARY:

MINOR 'KNOCKING' NOISE FROM THE STEERING INTERMEDIATE SHAFT

Situation:

A customer may report a concern of a minor 'knocking' noise coming from the front of the vehicle or a steering system component while driving over small bumps or undulating road surfaces. A low resistance in the sliding mechanism of the lower steering shaft may be the cause of the noise.

Action:

Should a customer express a concern related to the above condition, refer to the Repair Procedure detailed in this bulletin to diagnose and resolve the concern.





PARTS





WARRANTY:

NOTE:
Repair procedures are under constant review, and therefore times are subject to change; those quoted here must be taken as guidance only. Always refer to DDW to obtain the latest repair time.

DDW requires the use of causal part numbers. Labor only claims must show the causal part number with a quantity of zero.

Normal warranty policy and procedures apply.

REPAIR PROCEDURE

INSPECT AND REPAIR STEERING SHAFT ASSEMBLY





LR3 STEERING COLUMN AND I-SHAFT ASSEMBLY

NOTE:
All inspection and repair procedures must be completed before determining if an intermediate shaft should be replaced. Component references may be found in Figure 1.

1. Inspect the upper and lower intermediate shaft assembly as follows:

^ Inspect the upper intermediate shaft 'decoupler' assembly for excessive movement. (Arrowed in Figure 1 inset)

^ Inspect the upper intermediate shaft decoupler assembly and ensure the steel and rubber washers are correctly located. (Inset in Figure 1)

^ Verify that the fasteners joining the steering column universal joint to the upper intermediate shaft are tightened to *22 Nm (16 lbf-ft)*. (2 in Figure 1)

^ Inspect the joint between the upper intermediate shaft and lower intermediate shaft for any movement. (3 in Figure 1)

^ Inspect the joint between the lower intermediate shaft universal joint and steering gear for any movement. (4 in Figure 1)

^ Inspect the sliding mechanism of the lower intermediate shaft for any lateral 'play' or looseness. (5 in Figure 1)

2. If movement is discovered as quantified below, repair in sequence and as instructed:

^ If excessive movement exists in the upper intermediate shaft 'decoupler' assembly, replace the upper intermediate shaft (QLB500070).

^ If any of the decoupler assembly washers is incorrectly located, replace the upper intermediate shaft (QLB500070).

^ If any movement exists in the connection between the upper intermediate shaft and lower intermediate shaft, replace the retaining bolt (QYG10016L) and tighten to 30 Nm (22 lbf-ft). (3 in Figure 1)

^ If any movement exists in the connection between the lower intermediate shaft universal joint and steering gear, replace the retaining bolt (QYG000030) and tighten to 30 Nm (22 lbf-ft). (4 in Figure 1)

^ If any lateral 'play' or looseness exists in the sliding mechanism of the lower intermediate shaft, replace the lower intermediate shaft (QMN500250).

3. After replacing any components, ensure the integrity of the steering shaft assembly and fasteners.