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Steering - Steering Shaft Clunk on Acceleration/Turns



Bulletin No.: 06-006/08

Last Issued: 04/11/2008


BULLETIN NOTE This bulletin supersedes the previous bulletin 06-001/07, issued on 02/22/07. The APPLICABLE MODEL(S)/ VINs, and WARRANTY INFORMATION have been revised.

2003 - 2008 Mazda6
2006 - 2007 Mazdaspeed6

On some vehicles, the steering shaft may make an unusual clunk noise during acceleration while the steering wheel is turned. The intermediate shaft splines in the steering column may be lacking lubrication and causing the clunk noise.

Customers having this concern should have their vehicle repaired using the following repair procedure.

NOTE: Before performing this repair procedure, be sure to inform the customer that the new super grease is very effective for noise, but it may change the steering and handling feel of their vehicle. Also, the operation of the telescopic steering (if equipped) may feel slightly heavier after the repair.

1. Verify customer concern by changing steering column angle and length (telescoping only), then attempt to duplicate clunk noise.

WARNING: Do not attempt to adjust the steering column angle or length while driving the vehicle. Be sure to adjust the steering wheel only when the vehicle is stopped as you can lose control of the vehicle if you change the steering tilt or position while driving.

2. Repeat Step 1 two (2) more times using different steering column angles and lengths (telescoping only), then attempt to duplicate clunk noise.

- If clunk noise is gone, proceed to Step 3.

- If clunk noise is still present, do not proceed with this repair procedure. Troubleshoot other causes of noise according to related sections of the Workshop Manual.

3. For telescopic equipped vehicle: Position steering shaft to most forward position.

4. Remove two (2) push-nuts securing joint cover.

5. Remove joint cover.
6. Remove pinch-bolt securing intermediate shaft.

7. Slide shaft toward A to remove from steering gear.

8. Slide shaft toward B to remove from tube.

9. Wipe all grease off splines.

10. Apply approx. 5 cc of new super grease to splines and inside the tube.

11. Align marks and assemble tube and shaft.

12. Wipe off any extra grease.

13. Fit intermediate shaft to steering gear and tighten pinch bolt.

Tightening torque: 13.8 - 19.5 ft-lbf. (18.8 26.5 Nm, 1.9 - 2.7 kgfm)

14. Fit joint cover and reinstall two (2) push-nuts.

15. After reassembly, operate telescopic or tilt steering as follows:

- For vehicles equipped with tilt and telescopic: Operate telescopic three (3) times from front to rear. Operate tilt three (3) times from top to bottom, then return to original position.

- For vehicles equipped with tilt only: Operate tilt three (3) times from top to bottom, then return to original position.

16. Verify repair.