Detail: Popping noise from the front end during turns and over bumps. Front end has been shaken down with no failing parts. New struts and mounts, ball joints good, inner tie rods good, outer tie rods good, hub bearings good, sway bar link pins good. I've read the steering intermediate shaft tends to be noisy. However, while stopped and turning the wheel from clock to clock, the noise doesn't occur.
Solution: Yes the intermediate shaft is a problem on several GM vehicles, the trucks and suv's are the worst. If it sounds like a dull clunking noise and you can slightly feel it in the steering wheel this is most likely the culprit. You would not hear it just turning the wheel from Lock to Lock. The used to grease the shaft and reinstall it but now they recommend replacement. AJ , The top of the strut mount was not installed properly. , Hi, a 6ya Mechanic can help you resolve that issue over the phone in a minute or two. Best thing about this new service is that you are never placed on hold and get to talk to real repair professionals here in the US. click here to Talk to a Mechanic (only for users in the US for now) and get all the help you need. Goodluck!