Well, after steering box replacement, 2 intermediate shafts, and several lube jobs, I finally found what was making the clunk when turning the wheel.


AIR BAG MODULEhttp://www.dieselplace.com/forum/smileys/Geek.gif


Yep, the thing weighs around 2 lbs. and there was enough slop between the nylon bushings in the wheel and the 3/8" dia. pins in the bag housing that when the wheel was turned the bag module would fall from top to bottom. Just enough weight to let you feel it in the wheel and one of those deals that's easy to fix once you know where the problem is. Grab the bag module with your hand and see if you can move it side to side & top to bottom. If you can, & if you have too much free play, you'll feel the clunk and also hear it. Another check is to drive around and hold some pressure with your free hand on the module. If the clunk stops, Bingohttp://www.dieselplace.com/forum/smileys/Big Smile.gif





Fix: I took some .003" thick brass shim stock cut to 1/2" width and rolled it to fit tight on the two pins on the bag module. Place the two brass sleeves in the nylon bushings in the steering wheel. Make sure the split in the brass sleeves face away from the wheel so not to interfere with the wire clips that hold the bag module in place.


Smooth as silk now with no clunk or rattle. This may not be the problem with yours, but it was on mine. Horn works fine. Might be worth checking out.


Billy

Not to sound dumb, but is this inside the steering wheel itself? Could you be a little more specific on your walkthrough. I've been about to give in and take mine in, but I'd rather check this first.


Thanks
Mike

Interesting -- I think I may have the same problem. That and the steering shaft.


I heard that GM was coming out with a new steering shaft -- has anyone heard anything?

VFRRider


1)First pull the 15amp airbag fuse out of the box located on the driver's side of the dash


2)Get a small slot screwdriver with around a 6" long shaft and a thin blade. Start the engine and turn the steering wheel 90 deg. from centered.


3)Insert the screwdriver into the hole on the back side of the steering wheel and gently pull up on the screwdriver while pulling toward you on the air bag module. It can be a little tricky to get a hold on the release wire (spring steel wire, not electrical) so be patient. I'm sure GM has a special tool. Turn the steering wheel 180 deg. to the other side and do the same. The air bag module can be pulled toward you when both sides are released.


4)When the module is free from the steering wheel you need to disconnect the electrical plug. Pull out the little safety lock from the center of the plug first, then pull the plug itself from the module.


Now you will see the two steel 3/8" pins in the module and the two nylon bushings in the steering wheel. Put the bushings you make in the nylon bushings and not on the pins. Reconnect the electrical and gently push the module back into the steering wheel. Replace the fuse and you should be good to go.http://www.dieselplace.com/forum/smileys/Big Smile.gif Make sure the air bag warning light goes off and the horn still works. If it fits too tight the horn might stick.


Billy


Edited by: bhowell

Interesting -- I think I may have the same problem. That and the steering shaft.


I heard that GM was coming out with a new steering shaft -- has anyone heard anything?





I sure hope so! You would think that after 5 years of the same problem GM could figure this out. http://www.dieselplace.com/forum/smileys/Confused.gif

Well, you know how it goes and I'm sure most of us have been there more than once. Spend tons of money, time, many trips to the dealer, and one day the cheap or right answer pops up under your nose.


In this case.......literally! Unfortunately, this scenario takes place in all walks of life.http://www.dieselplace.com/forum/smileys/Cry.gif Like I said in my original post. This fixed mine but may not be the problem for others. With all that was replaced before, there could have been trouble there as well.


BillyEdited by: bhowell

Max,


The wheel and airbag are much different from the 99-02s to the 03-04s. I am sure that this case was just a one off fluke, because if this was always the case, people would be bringing their trucks in for the airbag flopping around. There are ~10million of the CKs out there, and I am certain that this would have come up in the early years.


All,


You are about to dive into messing with a safety system. Caution to you all....Follow the service procedure for the airbag system. I do not know it, nor have it, so maybe someone can post it. This is really a dealer job. If you do attempt this, at minimum, pull the fuse, wait 10 minutes, then start dissasembly. DO NOT have the key on. With the key off, the airbag system should not fire on its own. It will fire if you put voltage across the two leads though.

I was talking about the infamous steering shaft clunk not the air bag.

To All..........


Removing the air bag module from the steering wheel assembly could possibly result in an inadvertent or unexpected deployment of the bag if proper procedures are not followed. Serious injury could occur!http://www.dieselplace.com/forum/smileys/Dead.gif


However, the bushings I fabricated to remove exessive tolerance between the air bag module pins and the nylon bushings in the steering wheel will not affect air bag performance, if reinstalled properly.


Free travel of the air bag module to activate the vehichle horn could be restricted if the air bag module pins fit too tight within the nylon bushings in the steering wheel once the bushings are installed.


Billy