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Originally Posted by StevePT
I've got a slight clunk/pop in my steering system (97 GP SE) and I haven't spent the time to track it down, but I've done some research to see where GP owners commonly have loose steering issues.
It sounds like there was an issue with the yoke at the pinion getting loose and creating noise since the joint was dry. I believe there was a TSB and it included getting a tube of grease at the GM dealer and greasing that joint.
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On the Intermediate Steering Shaft noise, there are two GM TSBs out on the problem.
Here is a synopsis of the first GM TSB. It affected primarily 2001 - 2002 Chevy Monte Carlos and other GM vehicles to include other "W" bodies such as the Regal and Grand Prix which could be prone to a similar problem.
A clunk type noise from the front of the vehicle during a turning manuver - sometimes also felt through the steering wheel when the wheel is rotated from steering stop to steering stop when the vehicle isn't moving - may be caused by inadequate lubrication of the steering intermediate shaft. This results in a "slip stick" condition possibly resulting in the clunk noise (TSB 01-02-32-001B, July 2002)
A GM dealer should have a kit, GM #26098237. This kit contains instructions, a syringe of lube, and a rubber cork/stopper to plug yoke end of shaft when forcing lube into splines. Cost is approximately $12. A GM Kent-Moore tool to keep the steering column locked, as stated in the TSB is normally required but not necessary. Doing this repair could damage wiring on SIR coil, if wheel is turned excessively with ISS removed. GM's original TSB listed the lube kit as a fix, but the latest TSB calls for ISS (intermediate steering shaft) replacement.
TSB 01-02-32-001C - Sept 2003
Calls for ISS replacement.