2002 Pontiac Bonneville Problems

What owners report

Owners of this model year most often describe a clunking or banging noise and looseness felt through the steering column while turning, frequently returning even after the intermediate shaft or column parts were replaced. Coolant and oil leaks from the intake manifold and valve cover area, plus power window motors and regulators that quit, are the other recurring themes. Many reports come in at low to moderate mileage, in some cases within the first few years of ownership.

1. 1
   Steering

   Steering column clunk and loose steering feel

   • 18 complaints (20%)
   • median 21,205 mi at 3.3 yrs old (15 state mileage)
   • filed 2003–2011

   Owners describe a clunking, banging or popping noise felt through the steering wheel when turning, sometimes over small bumps, along with noticeable play or hesitation in the steering. Complaints say dealers cleaned and lubricated the intermediate shaft, replaced the shaft or column bearings, or changed the fluid in the steering mechanism, and that the noise often returned shortly afterward. Several owners report being told the condition was normal wear or that there was no risk of steering failure. Often reported between roughly 10,000 and 60,000 miles, sometimes recurring after each repair, and also again at higher mileage.

   What to check: Turn the wheel slowly at a standstill and over small bumps and listen or feel for a clunk, and check for play at the wheel. Ask for service records showing whether the intermediate shaft or column parts were replaced and when.

   2 excerpts from owner complaints in NHTSA records

   “Heard a clunking noise in the steering 9/02. The Pontiac service department cleaned and lubed the intermediate shaft. The same clunking noise came back in march 2005 this time the Pontiac service department said the intermediate shaft was worn and noisy. They replace the intermediate shaft under goodwill, but I had to pay $181.86 for labor. Now january 2007 the same clunking noise is back. I also have a 2003 gmc pickup that is doing the same thing. I would like to see a recall on GM intermediate shaft. …”

   NHTSA complaint #10178869, filed 2007-01, 13,140 miles

   “My 2002 Pontiac Bonneville has a banging noise in the steering column. I am concerned about loss of control of the car. I am told there is a safety defect bulletin on this issue but I do not know how to deal with this.”

   NHTSA complaint #10282503, filed 2009-09
2. 2
   Electrical system

   Stalling or no-start traced to ignition switch and

   • 13 complaints (15%)
   • median 104,509 mi at 12.2 yrs old (10 state mileage)
   • 1 mention a crash, fire or injury
   • filed 2004–2016

   Complaints describe the engine stalling at speed without warning, failing to start or needing several attempts, with the ignition switch, control module or general electrical fault identified as the cause. Some owners report the ignition switch and cylinder were replaced and the car still would not start, and others describe repeated blown fuses, a burning-wire smell or interior lights catching fire. Reported from about 80,000 to 145,000 miles, with some starting-concern reports earlier.

   2 related service bulletins

   What to check: Start the car several times cold and warm and confirm it catches promptly. Ask whether the ignition switch or security module has been replaced, and check that interior and exterior lights, trunk release and the OBD-II port all work.

   2 excerpts from owner complaints in NHTSA records

   “As I was driving, smelled wire burning and smoke coming from the front driver at the headliner then the interior lights shut off, trunk release switch inop. I pulled over on the highway and turned key off. Then noticed two weeks ago that there is no power to the obd-ii. Have able to repair the damages.”

   NHTSA complaint #10520327, filed 2013-06, 215,000 miles

   “While traveling on the interstate highway 295 in nj my vehicle stalled. The stalled and almost caused a near fatal accident with a semi. The vehicle after 20 minutes and numerous attempts the vehicle started back up and I decided to try and make it home by taking back roads away from the interstate. The vehicle stalled 4 more times before I could get it home. I was visibly shaken upset and scared out of my mind.”

   NHTSA complaint #10607729, filed 2014-07, 145,000 miles
3. 3
   Engine cooling

   Coolant and oil leaks at intake manifold and valve cover

   • 9 complaints (10%)
   • median 65,600 mi at 6.5 yrs old (7 state mileage, few)
   • 2 mention a crash, fire or injury
   • filed 2004–2016

   Owners describe coolant leaking from the upper and lower intake manifold gaskets, sometimes with a coolant smell or a low coolant level, and in one report coolant entering a cylinder after a manifold repair. Others report oil leaking onto the valve cover or manifold, burning-oil smell and smoke under the hood, with the gaskets and valve cover identified as the source. Complaints mention dealer quotes in the several-hundred-dollar range and, in some cases, contact with the manufacturer about assistance. Most reports fall between roughly 35,000 and 100,000 miles, often noticed as a smell, smoke or a dropping coolant level rather than a sudden failure.

   3 related service bulletins

   What to check: Look for coolant residue or staining around the intake manifold and oil residue around the valve cover, check the coolant and oil levels, and ask whether the intake manifold gaskets have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “- the contact states that the engine coolant is leaking at the upper intake manifold. The contact states that there was a safety campaign regarding the same issue he has with his vehicle and that he wasn't aware about the issue until he was doing research online. By the time the contact found out about the safety campaign the time for the campaign had expired. …”

   NHTSA complaint #10176733, filed 2006-12, 60,000 miles

   “3/13/2007 coolant leak in lower and upper gaskets at 65,600 miles. Required removal and replacement of lower and upper gaskets and upper intake manifold. Evidently a GM problem with gaskets. $700 repair on car that has been well taken care of by original owner and only driver of vehicle.”

   NHTSA complaint #10200415, filed 2007-08, 65,600 miles
4. 4
   Visibility (wipers, defrost, mirrors)

   Power windows stop working or fall off track

   • 9 complaints (10%)
   • median 33,212 mi at 5.0 yrs old (5 state mileage, few)
   • filed 2002–2007

   Complaints describe power windows that stop moving without warning, stick in the down position, or drop off their track, and owners say the diagnosis was usually a failed window motor or regulator. Reports include repeat failures on several doors, parts on back order, and repairs paid by the owner after warranty. Some describe water leaking past the door and window seals into the cabin, leaving wet carpeting. Reported from about 25,000 to 65,000 miles, with repeat failures on multiple doors as the car ages.

   What to check: Operate every window up and down through a full cycle and listen for slow or grinding movement. Check carpets and door trim for dampness after rain, and ask whether any window motors or regulators have been replaced.

   2 excerpts from owner complaints in NHTSA records

   “Problems with window regulator design. 3/30/2005 33,212 miles, driver's side window shudders and stopped working, would not open. Window replaced under warranty. 3/13/2007 65,600 miles, rt front passenger window, would not open, required replacement, cost to repair $500 8/20/2007 drivers window again barely working, and will need replacement for $500. Obviously a flaw if design of window regulators. Posing danger if can not open window.”

   NHTSA complaint #10200414, filed 2007-08, 33,212 miles

   “Late march 2007 rear driver window would not work. Electric motor cable twisted. Cost $400. At this time back passenger window will not work. Fell off track , possible motor cable problem . Front passenger window will not work. Froze in position.”

   NHTSA complaint #10190838, filed 2007-05, 62,000 miles

Buying note. These reports are mostly about wear-type problems that a careful test drive and service records can reveal: listen for steering clunks, cycle every window, and check for coolant and oil leaks around the intake and valve cover. Ask what has already been replaced, since several owners describe repeat repairs on the same part.

Summary written with AI from a sample of 60 NHTSA complaints for this model year (picked at random, with complaints that state a mileage and recent ones taken first), then checked automatically against the source records. Where a problem shows a complaint count, every complaint for this model year was matched with fixed keyword rules (written with AI and tested against the sample), and the mileage, age and repair figures are calculated from those complaints; owners' figures are as stated, not verified. Other counts refer to the sample. The excerpts come from NHTSA's public complaint records and are unverified; capitalisation is normalised, NHTSA staff notes are removed, and shortened text ends with “…”. Something wrong? Request a correction.