uhm, did anyone perform this TSB?
This is probably the cure for your vehicle, unfortunately it isn't likely to be covered under warranty, so it will be your dime.
My concern is that all this stuff was replaced and not one place knew enough to know that this was a common problem???
Bulletin No.: 01-02-32-001J
Date: June 08, 2007
Clunk Felt/Noise Heard From Steering Column, Steering Gear and/or Front Of Vehicle During Turning Maneuver and/or Steering Wheel Rotation (Lubricate or Replace Intermediate Shaft As Appropriate)
2001-2004 Buick Regal
2005-2007 Buick Allure (Canada Only), LaCrosse
1997-2005 Chevrolet Cavalier
2000-2007 Chevrolet Impala, Monte Carlo
1998-2002 Oldsmobile Intrigue
1997-2005 Pontiac Sunfire
2004-2007 Pontiac Grand Prix
Some customers may comment on a clunk type noise coming from the front of the vehicle while driving during a turning maneuver. This condition may also be felt through the steering wheel when the vehicle is stationary and the wheel is rotated from steering stop to steering stop. Some vehicles may only exhibit the noise once for every 360°of wheel rotation. On all other vehicles, this clunk noise will be noticed during low speed acceleration or deceleration, typically in light turns of the steering wheel.
This condition may be caused by inadequate lubrication of the steering intermediate shaft which results in a slip stick condition possibly resulting in the clunk noise.
Due to the design of the new I-shaft, it is not possible to lubricate/grease the I-shaft.
Replace the existing steering intermediate shaft using the service procedure found in Service Information. The remaining vehicles listed below will still need to have the current I-shafts re-lubricated. New I-shafts will be released later in 2007 for some of the remaining vehicles.
Shaft assembly - Steering gear Part number 25829294 00-05 Impala