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DRIVELINE/AXLE

Wheel Drive Shafts - Volt

SPECIFICATIONS

FASTENER SPECIFICATIONS

Single Use Non-Threaded Fasteners/Components

Single Use Threaded Fastener/Component Tightening Specifications

ADHESIVES, FLUIDS, LUBRICANTS, AND SEALERS

DIAGNOSTIC INFORMATION AND PROCEDURES

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SYMPTOMS - WHEEL DRIVE SHAFTS

IMPORTANT: Complete the following steps prior to beginning the wheel drive shaft diagnosis.

1. Review the Vibration Diagnosis, Starting Point, and Correction .

2. Perform the Vibration Analysis - Road Testing (EL-38792-A Electronic Vibration Analyzer) Vibration Analysis - Road Testing (CH-51450-NVH Oscilloscope) in order to effectively diagnose the concern.

3. Review the system operation in order to become familiar with the system function. Refer to Wheel Drive Shafts Description and Operation

Visual/Physical Inspection

Inspect for aftermarket equipment and modifications which could affect the operation of the wheel drive shafts or other rotating components.

Inspect the easily accessible or visible system components for obvious damage or conditions which could cause the symptom.

Thoroughly inspect the entire wheel drive shaft for visible damage, leaking joint seals, and missing seal clamps.

Inspect the wheel drive shaft seals for cuts, tears, or other damage which may allow the loss of lubricant and the entry of contaminants.

Symptom List

After performing the Visual/Physical Inspection and no visual signs of damage or other interference impairing the wheel drive shaft function is apparent, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the joints manually. Any binding or otherwise impeded movement of the joints may indicate damage which could contribute to the concern. Refer to the following:

Click Noise In Turns

Clunk When Accelerating from Coast

Clunk Noise When Accelerating During Turns Shudder or Vibration During Acceleration

CLICK NOISE IN TURNS

A click noise occurring during turns may be caused by a worn or damaged wheel drive shaft outer joint. This may be more apparent while simultaneously turning and accelerating. This click is caused by wear and/or damage to the constant velocity joint bearings and/or races. Commonly, this damage or wear is caused by the loss of lubricating grease from the constant velocity joint and the entry of foreign material or contaminates.

Carefully inspect the wheel drive shaft seals for cuts, tears or other damage which may allow the lubricating grease to escape. The loss of this grease will cause damage to the wheel drive shaft constant velocity joint in a very short period of time.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the outer joint manually. Any binding or impeded movement of the joint may indicate damage which could contribute to the concern.

CLUNK WHEN ACCELERATING FROM COAST

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A clunk noise occurring when accelerating from coast or a standing start may be caused by a worn or damaged wheel drive shaft inner joint. The common cause of wheel drive shaft inner joint damage is the loss of lubricating grease and/or the presence of foreign material and contaminates in the joint. This usually occurs as a result of a torn or damaged inner joint seal.

Carefully inspect the wheel drive shaft seal for cuts, tears or other damage that may allow the loss of the lubricating grease and/or the entry of contaminates.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the inner joint manually. Do not allow the joint to separate from the wheel drive shaft bar. Any binding or impeded movement of the joint may indicate damage which could contribute to the concern.

CLUNK NOISE WHEN ACCELERATING DURING TURNS

A clunk noise that occurs while accelerating during turns may be caused by wear and/or damage to the inboard and the outboard joints in combination. The loss of lubricant and/or the presence of contaminates can cause damage to the internal components of the joints.

Carefully inspect the joint seals for cuts, tears or other damage. Joint seals that are damaged may allow lubricant leakage and the entry of contaminates.

If inspection reveals no visual evidence of wear or damage, it may be necessary to remove the wheel drive shaft from the vehicle and manipulate the joints manually. Do not allow the joints to separate from the wheel drive shaft bar.

Any binding or impeded movement of the joints may indicate damage which could contribute to the concern.

SHUDDER OR VIBRATION DURING ACCELERATION

In order to diagnose a shudder or vibration during acceleration, refer to Vibration Diagnosis, Starting Point, and Correction .

REPAIR INSTRUCTIONS

FRONT WHEEL DRIVE SHAFT REPLACEMENT

Special Tools

CH-28733-B Wheel Hub and Driveshaft Remover

DT-51504 Seal Protector

EN-45059 Angle Meter

Equivalent regional tools: Special Tools

Removal Procedure

1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle

2. Remove the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .

3. Remove Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

4. Remove Front Wheelhouse Liner. Refer to Front Wheelhouse Liner Replacement (Left Side) Front Wheelhouse Liner Replacement (Right Side)

5. Remove Stabilizer Shaft Link. Refer to Stabilizer Shaft Link Replacement

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Fig. 1: Holding Brake Rotor From Turning Using Drift Courtesy of GENERAL MOTORS COMPANY

6. Insert a drift or a punch (1) in the brake rotor cooling fins.

7. Rotate the brake rotor until the drift or punch is resting against the brake caliper mounting bracket.

8. Using a breaker bar and the proper size socket (2), loosen the wheel drive shaft nut.

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Fig. 2: Wheel Drive Shaft Nut

Courtesy of GENERAL MOTORS COMPANY

9. Remove and DISCARD Wheel Drive Shaft Nut (1)

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Fig. 3: Separating Wheel Drive Shaft From Wheel Hub/Bearing Courtesy of GENERAL MOTORS COMPANY

10. Using the CH-28733-B remover (2), separate the wheel drive shaft from the front wheel hub (1).

11. Disconnect the outer tie rod from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

12. Remove the lower control arm ball joint from the steering knuckle. Refer to Steering Knuckle Replacement

NOTE: Position a drain pan under the transmission when servicing the wheel drive shaft.

13. With the aide of an assistant, move the front knuckle assembly to the side.

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Fig. 4: Removing Wheel Drive Shaft Using Large Flat Bladed Tool Courtesy of GENERAL MOTORS COMPANY

14. Using a large flat bladed screwdriver or pry bar (2), remove the wheel drive shaft (1) from the differential.

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Fig. 5: Wheel Drive Shaft

Courtesy of GENERAL MOTORS COMPANY

15. Remove Wheel Drive Shaft (1) @ Vehicle

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Fig. 6: Axle Shaft Retaining Ring

Courtesy of GENERAL MOTORS COMPANY

16. DISCARD the retaining ring.

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Fig. 7: Wheel Drive Shaft And Washer Courtesy of GENERAL MOTORS COMPANY

NOTE: If there is no washer on the wheel drive shaft, install a NEW washer.

17. Remove and DISCARD the washer (1) from the front wheel drive shaft (2).

Installation Procedure

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Fig. 8: Axle Shaft Retaining Ring

Courtesy of GENERAL MOTORS COMPANY

1. Install the NEW retaining ring to the front wheel drive shaft inner joint. Start to pull the ring from the front wheel drive shaft inner joint end down to the ring groove.

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Fig. 9: Differential Output Shaft Seal Protector Courtesy of GENERAL MOTORS COMPANY

CAUTION: DT-6332/DT-51504 or equivalent must be installed into the front wheel drive shaft oil seal prior to removing and installing the front wheel drive shaft.

Failure to use the DT-6332/DT-51504 may cause the spline of the front wheel drive shaft to cut the front wheel drive shaft oil seal. Damage to the front wheel drive shaft oil seal will result in lubricant leaks.

2. Install the DT-51504 protector (1) into the differential.

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Fig. 10: Wheel Drive Shaft

Courtesy of GENERAL MOTORS COMPANY

3. Install the wheel drive shaft into the differential until the retaining ring is fully seated. (1)

4. With the aide of an assistant, move the front knuckle assembly into the proper position.

5. Install the wheel drive shaft in the front wheel hub.

6. Install the lower control arm ball joint to the steering knuckle. Refer to Steering Knuckle Replacement .

7. Connect the outer tie rod to the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement .

8. Install Stabilizer Shaft Link. Refer to Stabilizer Shaft Link Replacement

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Fig. 11: Wheel Drive Shaft Nut

Courtesy of GENERAL MOTORS COMPANY

NOTE: Do NOT tighten.

9. Loosely install Wheel Drive Shaft Nut (1)

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Fig. 12: Holding Brake Rotor From Turning Using Drift Courtesy of GENERAL MOTORS COMPANY

10. Insert a drift or a punch (1) in the brake cooling fin.

11. Rotate the brake rotor until the drift or the punch is rest against the brake caliper mounting bracket.

12. Tighten Wheel Drive Shaft Nut

1. First Pass: 150 N.m (111 lb ft)

2. Second Pass: - Loosen 45 degrees, use the EN-45059 meter

3. Final Pass: 250 N.m (184 lb ft)

13. Install Front Wheelhouse Liner. Refer to Front Wheelhouse Liner Replacement (Left Side) Front Wheelhouse Liner Replacement (Right Side)

14. Install Front Compartment Splash Shield. Refer to Front Compartment Splash Shield Replacement

15. Install the front tire and wheel assemblies. Refer to Tire and Wheel Removal and Installation .

16. Lower the vehicle.

DESCRIPTION AND OPERATION

WHEEL DRIVE SHAFTS DESCRIPTION AND OPERATION

Front wheel drive axles are flexible assemblies.

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Front wheel drive axles consist of the following components: A front wheel drive shaft tripot joint (inner joint)

A front wheel drive shaft constant velocity joint (outer joint) A front wheel drive shaft

The front wheel drive shaft connects the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joint.

The front wheel drive shaft tripot joint is completely flexible. The front wheel drive shaft tripot joint can move in and out.

The front wheel drive shaft constant velocity joint is flexible, but the front wheel drive shaft constant velocity joint cannot move in and out.

Boots And Clamps

The front wheel drive shaft constant velocity joint and the front wheel drive shaft tripot joint boots in the front wheel drive axle are made of a thermoplastic material.

The clamps in the front wheel drive axle are made of stainless steel. The boot provides the following functions:

Protection of the internal parts of the front wheel drive shaft constant velocity joint and the front wheel drive shaft tripot joint

The boot protects the grease from the following sources of damage:

Harmful atmospheric conditions, such as extreme temperatures or ozone gas Foreign material, such as dirt or water

Allows angular movement and the axial movement of the front wheel drive shaft tripot joint Allows angular movement of the front wheel drive shaft constant velocity joint

NOTE: Protect the boots from sharp tools and from the sharp edges of the surrounding components. Any damage to the boots or the clamps will result in leakage. Leakage will allow water to leak into the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joints. Leakage will also allow grease to leak out of the front wheel drive shaft tripot joints and the front wheel drive shaft constant velocity joints. Leakage may cause noisy front wheel drive axle operation and eventual failure of the internal components.

The clamps provide a leak proof connection for the front wheel drive shaft tripot joint and the front wheel drive shaft constant velocity joint at the following locations:

The housing

The front wheel drive shaft

The thermoplastic material performs well under normal conditions and normal operation. However, the material is not strong enough to withstand the following conditions:

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Abusive handling

Damage from sharp objects, such as sharp tools or any sharp edges of the surrounding components in the vehicle

Front Wheel Drive Shaft Tripot Joint (Inner Joint)

The front wheel drive shaft tri-pot joint is made with the tripot design without an over-extension limitation retainer. The joint is constructed as follows for vehicles that are equipped with an automatic transmission:

The left front wheel drive axle has a female spline. The female spline installs over a stub shaft that protrudes from the transaxle.

The right front wheel drive axle has a female spline. The right front wheel drive axle uses barrel type snap rings in order to interlock with the intermediate shaft.

Front Wheel Drive Shaft Constant Velocity Joint (Outer Joint)

The front wheel drive shaft constant velocity joint is made with the Rzeppa joint design.

The shaft end (which mates with the knuckle/hub) has a helical spline. The helical spline ensures a tight, press-type fit.

This design prevents end play between the hub bearing and the front wheel drive axle.

SPECIAL TOOLS AND EQUIPMENT

SPECIAL TOOLS

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