Chevrolet Sonic Repair Manual: Wheel Drive Shafts Description and Operation

Front wheel drive axles are flexible assemblies.

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:

• 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.