The part in question is the rack and pinion assembly part # 25902150 of a Chevy Malibu maxx 2004. The first part was replaced July 8 2008, that part failed and was replaced again on October 3 2008. That part is now failed again and it has not been 3 moths since it was replaced. So the part has failed by making extreme noise, clicking or thumping heard in the front end. My mechanic told me that the GM dealer that provided the part told him they keep many in stock because they have this problem a lot. My mechanic also tells me that GM refused to pay his labor cost even though they admitted the part failure in such a short time. My mechanic tells me that not replacing the part can result in my losing control of my vehicle and possibly at risk of causing serious injury to me or others.

- Wheaton, IL, USA

Car has had rattle noise from front end since car was bought from a Chevy dealership with 32K on it. The car currently has 61K on it. Steering rack has worn to the point where it jams and the wheel will not turn. Rattle noise has turned in to clunking noise. When car was brought to dealer 3 times for noise it was returned "no problems found".

- Coon Rapids, MN, USA

Gear shift locked up and would not move. Had to be towed to dealer for repair. Front turn lights constantly loose connection and go out. Have replaced them on average every three months. Within 6 mo of purchase, steering felt loose and would lock up a slow speed turns. Steering column was replaced. At the same time, thumping can be heard with left hand turns. Dealer says the problem is recognized by Chevrolet and is a design defect of the rack and pinion, but Chevrolet says they have no reports of the problem. The shop just greases the rack and pinion and sends me on my way. After the 5th time of having in the shop and Chevy refusing to do anything but give me free oil changes, I have traded in the car for a Ford.

- Crosby, TX, USA

Around 40,000 miles on odometer, a thunk could be heard when turning steering wheel left. Dealership where car was purchased could not determine cause. At 45,000 miles on odometer, took vehicle to 2nd dealership who knew of a technical bulletin - rack and pinion steering unit was failing.

- Zionsville, IN, USA

Noisy, grinding sound + stiffness in steering. Have had to dealer (john kennedy Chevrolet, southampton, pa) 3 times beginning 2/15. 1st diagnosis: Underinflated tires. Result: No change. 2nd diagnosis: Worn steering column. Action: Replaced column. Result: No change. 3rd diagnosis: Problem with steering rack. Action: Replace rack. Result: No change. This problem only happens when the air temperature is warm (won't happen on a cool morning, but is present after sitting in the sun all day). It seems that when the metal heats up, it expands & causes binding.

- Southampton, PA, USA