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My 2011 volt has 91100 miles on it now and is running great.

It did generate the CV joint clicking about 20-30k miles ago, my wife took it to the dealer over a year ago and they found nothing wrong so we left it.

A few months ago I decided to check the torque on the end nuts to the wheel hubs, I checked both of them and they were snug, not loose. The CV boots seem in good shape, no tears or damage or lost grease.

As I have less than 9k miles on warrantee left should I bother taking it in? it hasn't gotten any worse and I try and avoid extreme steering wheel turns while accelerating or braking.

Has anyone had any actual failure from this noise? if its just annoying I can live with it, it doesn't bother me that much. I do plan on keeping this car as long as possible. thanks!
 

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The clicking is a symptom of a failure, of a CV joint or something else. Assuming it is a CV joint, unless you like watching your wheel go down the street you probably want to get it fixed. Take it in. The worst that happens is they tell you there isn't a problem, which means that when the wheel goes down the street it's their problem.
 

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Has anyone had any actual failure from this noise?
Yes, but not in the Chevy Volt. My Dad bought a 1968 Austin America, whcih was our first car with an automatic transmission and where we (me and my siblings) all learned how to drive in. In 1974, the CV joint on the right side began clicking loudly, and my Dad suspected that it was caused by the car hitting the entry ramp edge first on the right side for all those years (several times a day). The replacement was done by our family mechanic in three hours. The left side never needed replacement. He sold that car in 1977, and the new owner never had any CV joint problems later.
 

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Any clicking you can hear in the car, windows up, when turning is not normal. If the windows are down and you hear a very mild click when the sound is reflected back to you off a wall or something, that would be normal.

If it is the loud version, you have a bad CV joint and should certainly be fixed under warranty, especially if it is happening with only slight turning. It will never get better, only worse.
 

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Since it is covered under warranty, there is absolutely no reason not to get it fixed. Both left and right CV joints of my 2013 Volt went out around 55000 and 59000 and were done by different dealers, in different states with no questions, free of charge. One dealer replaced the CV joint on the left, another replaced the whole axle on the right. Get it fixed and be safe
 

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CV joints normally give you lots of warning before failure. If the boots are not torn I personally have not seen one fail. We had a new 2002 Saturn that came from the factory with a tiny tear in the boot where the clamp had been installed. The tear gradually grew over time, and I kept trying to patch it with caulking. Of course it didn't work and the joint finally started making clunking noises in sharp turns. That joint lasted 200000 miles before it got changed, and did not fail! The joint on the other wheel is original and still quiet (sold the car to my neighbor).
 

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There was a manufacturing issue with the axles. I have two 2012 Volts and I have had three of the four axles replaced under powertrain warranty.

I thought the powertrain warranty expired at 60,000 miles and you would be on your own unless you have an extended warranty or there are different warranty rules in California.
 
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