My Bolt is in the shop today, Tuesday March 13th. Seems that my problem is NOT
the issue of improper torque on the steering shaft bolts. The part required is the F-Bar (PN: 42592104). Replacing requires major surgery to the dash. The dealership is keeping my Bolt for the week while they remove the dash and replace these parts. They say it might be ready by Friday.
When I asked the service manager about the replacement it seems like welds for the aluminum F-Bar might not
have been done correctly on some of the early Bolts (my VIN ends in 128602 built in Nov 2016). Below you can see the part. The the dash structure is held together by the F-Bar. The service manager circled the part on the first picture. I hope they don't damage anything else while the do brain surgery on my Bolt!F-BAR
metal structure circled:*** UPDATE: 3/14/2018 ***
It's Pi-day (3.1415...). I got a call today saying my Bolt was ready for pickup. Amazing, only two days in the shop. The previous service manager was out and my new service manager didn't know exactly why the F-bar needed to be replaced. Bad welds?.. "I don't know." Bad part? "Not sure"... Maybe the service report (below) will have some clues.
First off here's a few pictures during disassembly:
Here's a picture of the OLD
part after it was removed from the car (not much to see):
Now here's the service report. Pay attention to the highlighted yellow parts. I'm not sure what the technician means by "ORIGINATE AT MOTOR".. What "motor" is he talking about. TAC told him to replace the "TIE BAR" but again, I'm not sure where the tie bar is located.
One thing I should note is two weeks after the original appointment to diagnose the noise, I returned to the service department once the replacement parts had arrived, and the clicking noise was almost gone. I mean I could barely hear it. So if you even remotely hear a clicking noise when you turn your steering wheel, I would take it directly into the dealership.
Based on what I could tell from how quickly GM wanted to replace this part, they've seen it before and probably more than once before. Who knows if it's a safety thing or is only limited to a small number of Bolts. Chime in if you've had this issue or know of other bolts with this Clicking issue.
So there you have it. My Bolt is back in one piece and seems to be in working order. PLEASE post if you that have seen similar.
BTW: My Bolt is a November 2016