I removed, lubed, replaced it twice with GM Lube kit . Each time it only last for 10 - 15,000 miles. Has there been any recall's, or part changes to get rid of the "CLUNK"....my dealer doesn't know of any.
Intermediate Steering Shaft "Clunk" on 2005 Chevrolet Malibu Maxx
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There is an updated service bulletin for the steering clunk in your 2005 Chevrolet Malibu Maxx. The number is 06-02-32-007F. This bulletin addresses various intermediate shaft designs and steering systems available on the different Malibu's. Who ever does the service work outlined in this bulletin will need to be very careful that they perform the correct repair for the type of steering system on YOUR Malibu.
My 2005 malibu does the same clunk, clunk, when driving down dirt roads. I thought it was normal, guess not.