Rattle/Clunk - Driver Side Front End

[Firesource]

have an '05 1/2 ton Crew Cab Silverado. At about 8000 miles, I began to hear a rattle / clunk in the front driver side area on uneven pavement.

 

1. 1st service appt ---- replaced driver side shock >> no change.

2. 2nd service appt ---- replaced intermediate steering shaft >>> no change

3. 3rd service appt ---- replaced front end body mounts >>> no change

 

I'm no mechanic, but it sounds like it has to do with compression and/or flexing of the front end when you either go over a bump, or across uneven pavement. Dealer is stumped. They don't have any other ideas --- and are unsure what to do.

 

Does anyone have any other ideas? I've lived w/this for 7,000 miles now and frankly, it's very discouraging. I can't be the only one experiencing this type of problem.

 

Thanks in advance for any help.

[ChevyTech007]

If it happens on turns I would suggest this.

 

Subject: Snap/Popping Type Noise Coming from Front of Vehicle (Remove Bolt-In Front Crossmember and Add Washers) #03-08-61-002G - (02/14/2006)

 

 

 

Models: 2003-2006 Cadillac Escalade

 

2003-2006 Chevrolet Avalanche, Suburban, Tahoe

 

2004-2006 Chevrolet Silverado

 

2003-2006 GMC Yukon, Yukon XL

 

2004-2006 GMC Sierra

 

1500 Series (½ Ton) and 2500 Series (¾ Ton) with Two-Wheel Drive

 

 

 

Attention: This bulletin only applies to 1500 and 2500 series 2WD vehicles with recirculating ball type steering.

 

 

 

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This bulletin is being revised to add the 2006 model year, update the correction information and change the quantity of parts needed. Please discard Corporate Bulletin Number 03-08-61-002F (Section 08 -- Body and Accessories).

 

 

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Condition

Some customers may comment on a snap or popping-type noise coming from the front of the vehicle. This condition is most apparent during hard left or right turns at low speeds. Going over bumps while turning may also aid in producing this noise.

 

Correction

Remove the bolt-in front crossmember and add washers using the procedure listed below.

 

Important: DO NOT slot the mounting holes on the crossmember as stated in previous bulletins. Slotting the holes has been found to be less effective and, in some cases, causes the noise condition to be more prevalent.

 

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in the General Information sub-section of the Service Manual.

Remove the mounting nuts, bolts and the front crossmember from the vehicle.

Clean all the undercoating off the crossmember in the area of the mounting holes.

Reinstall the crossmember with the bolts and nuts. On the driver and passenger side, add washer P/N 11509592, or equivalent hardened washer (see dimensions below), at each bolt head and nut location.

Tighten

Tighten the bolts to 120 N·m (89 lb ft).

 

Apply an even coat of Anti-Corrosion Coating, P/N 12346501, or equivalent, to the crossmember where removed. Overlap the original coating in order to provide an effective corrosion protection.

Inside Diameter

Outside Diameter

Thickness

 

14 mm (0.551 in)

35 mm (1.38 in)

3 mm (0.118 in)

 

 

Parts Information

Part Number

Description

Qty

 

11509592

Washer

8