Student Workbook

70-1805-W 10-1831-T
Module 5: Steering and Suspension Systems
Automotive Technology Curriculum
2006 2005 Edition Student Test Workbook Packet
STEERING AND SUSPENSION SYSTEMS
Automotive Technology Module 5: Steering and Suspension Systems Student Workbook

Technical Consultants: Roger Donovan Robin Ferguson
Project Coordinator: Erica Kassel
Editor: Janis Levsen
Produced by the Instructional Materials Laboratory 1400 Rock Quarry Center University of Missouri-Columbia Columbia, MO 65211 (800) 669-2465 http://www.iml.missouri.edu 2006 Edition Catalog no. 70-1805-W 2006. The Curators of the University of Missouri. All Rights Reserved.
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Graphic Artists: Chris Benedict Jacqueline Craig
AUTOMOTIVE TECHNOLOGY
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Name: MODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET
Assignment Sheet AS1-L1-UI AS1-L1-UII AS1-L2-UII AS1-L3-UII AS1-L1-UIII AS1-L1-UVI AS1-L2-UVI AS1-L1-UVII AS1-L2-UVII AS1-L3-UVII AS1-L1-UX AS1-L1-UXI AS1-L1-UXII AS1-L2-UXII AS1-L3-UXIII AS1-L1-UXIV AS1-L2-UXIV Job Sheet JS1-L2-UI JS2-L2-UI JS1-L4-UII JS2-L4-UII JS3-L4-UII JS1-L1-UIII Title of Assignment Sheet Steering and Suspension Systems Types of Steering Systems Conventional Steering System Components Rack-and-Pinion Steering Systems Steering Gear Concerns Energy-Absorbing Steering Column Air Bag Systems Suspension Systems Front Suspension Types and Components Rear Suspension Types and Components Electronic Suspension Control Systems Wheel Bearings Wheel Basics Tire Basics Wheel Balance and Runout Steering, Suspension, and Wheel Alignment Concerns Wheel Alignment Principles Title of Job Sheet Complete a Work Order With Concern, Cause, and Correction Identify and Interpret a Steering and Suspension Concern Inspect and Adjust Manual Steering Gear Lubricant Level Inspect and Adjust Power Steering Fluid Levels Diagnose Fluid Leaks in the Power Steering System Diagnose Manual and Power Steering Gear Concerns Instructor Guide Page # 1114 4750 7982 9194 141144 345348 355358 401404 433436 443446 623626 663666 707710 723726 787790 827830 845848 Instructor Guide Page # 1920 2124 105106 107108 109110 145146 Student Workbook Page # W 12 W 910 W 1112 W 1314 W 2122 W 103104 W 105106 W 121122 W 123124 W 125126 W 191192 W 203204 W 215216 W 217218 W 237238 W 245246 W 251252 Student Workbook Page # W 34 W 58 W 1516 W 1718 W 1920 W 2324 Date Instructors Initials Date Instructors Initials
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MODULE 5: STEERING AND SUSPENSION SYSTEMS STUDENT WORKBOOK TRACKING SHEET PAGE 2
Job Sheet JS1-L2-UIII JS2-L2-UIII JS3-L2-UIII JS1-L3-UIII JS2-L3-UIII JS3-L3-UIIII JS1-L4-UIII JS2-L4-UIII JS3-L4-UIII JS4-L4-UIII JS5-L4-UIII JS1-L1-UIV JS2-L1-UIV JS3-L1-UIV JS4-L1-UIV JS1-L2-UIV JS2-L2-UIV JS3-L2-UIV JS4-L2-UIV Title of Job Sheet Remove and Install a Manual Steering Gear Disassemble, Clean, and Inspect a Manual Steering Gear Reassemble and Adjust a Manual Steering Gear Remove and Install an Integrated Power Steering Gear Disassemble, Clean, and Inspect an Integrated Power Steering Gear Reassemble and Adjust an Integrated Power Steering Gear Inspect and Replace a Pitman Arm Inspect and Replace a Center Link Inspect and Replace Tie-Rod Ends Inspect and Replace an Idler Arm Inspect and Replace a Steering Damper Remove and Install a Manual Rack-andPinion Steering Gear Inspect and Replace Rack-and-Pinion Inner Tie-Rods and Bellows Boots Disassemble, Clean, and Inspect a Manual Rack-and-Pinion Steering Gear Reassemble and Adjust a Manual Rack-andPinion Steering Gear Remove and Install a Power Rack-and-Pinion Steering Gear Disassemble, Clean, and Inspect a Power Rack-and Pinion Steering Gear Reassemble and Adjust a Power Rack-andPinion Steering Gear Test and Diagnose Components of Electronically Controlled Steering Systems Using a Scan Tool Inspect and Test Nonhydraulic Electric Power-Assist Steering Replace Rack Boots (End Take-Off Units) Replace Rack Mount Bushings Test Power Steering System Pressure Instructor Guide Page # 155158 159160 161162 171174 175178 179180 195198 199200 201204 205206 207208 233234 235238 239240 241242 253254 255256 257258 259260 Student Workbook Page # W 2528 W 2930 W 3132 W 3336 W 3740 W 4142 W 4346 W 4748 W 4952 W 5354 W 5556 W 5758 W 5962 W 6364 W 6566 W 6768 W 6970 W 7172 W 7374 Date Instructors Initials
JS5-L2-UIV JS1-L3-UIV JS2-L3-UIV JS1-L1-UV
261262 267268 269270 287290
W 7576 W 7778 W 7980 W 8184
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Job Sheet JS1-L2-UV JS2-L2-UV JS3-L2-UV JS4-L2-UV JS5-L2-UV JS6-L2-UV JS7-L2-UV Title of Job Sheet Remove and Install a Power Steering Pump Inspect and Replace Power Steering Pressure Hoses Service a Power Steering Pump Inspect, Replace, and Adjust the Power Steering Pump Belt Flush the Power Steering Gear Flush the Power Steering Pump Identify Hybrid Vehicle Power Steering System Electrical Circuits Service and Safety Precautions Identify Vehicles Equipped With a Supplemental Restraint System (SRS) Disable and Enable a Supplemental Restraint System (SRS) Remove and Install a Steering Wheel on a Vehicle Equipped With a Supplemental Restraint System (SRS) Diagnose Steering Column Concerns and Remove and Install an Energy-Absorbing Steering Column Disassemble, Inspect, and Reassemble an Energy-Absorbing Steering Column Diagnose a Short- and Long-Arm (SLA) Suspension System Lubricate a Steering and Suspension System Inspect and Replace Conventional or GasCharged Shock Absorbers Inspect and Replace Air-Adjustable Shock Absorbers Inspect and Replace Stabilizer Bars and Bushings Inspect and Replace Strut Rods and Bushings Inspect and Replace Coil Springs Inspect and Replace Torsion Bar Springs Inspect and Replace Ball Joints Inspect and Replace Lower Control Arms and Bushings Inspect and Replace Upper Control Arms and Bushings Instructor Guide Page # 307310 311312 313316 317318 319320 321322 323324 Student Workbook Page # W 8588 W 8990 W 9194 W 9596 W 9798 W 99100 W 101102 Date Instructors Initials
JS1-L3-UVI JS2-L3-UVI JS3-L3-UVI
369370 371372 373374
W 107108 W 109110 W 111112
JS4-L3-UVI
375378
W 113116
JS5-L3-UVI JS1-L1-UVIII JS2-L1-UVIII JS1-L2-UVIII JS2-L2-UVIII JS3-L2-UVIII JS4-L2-UVIII JS1-L3-UVIII JS2-L3-UVIII JS3-L3-UVIII JS4-L3-UVIII JS5-L3-UVIII
379382 475480 481482 493496 497500 501502 503504 521524 525528 529530 531534 535538
W 117120 W 127132 W 133134 W 135138 W 139142 W 143144 W 145146 W 147150 W 151154 W 155156 W 157160 W 161164
Job Sheet JS1-L4-UVIII JS2-L4-UVIII JS3-L4-UVIII JS1-L1-UIX JS2-L1-UIX JS3-L1-UIX JS4-L1-UIX JS5-L1-UIX JS1-L2-UX JS2-L2-UX JS3-L2-UX JS4-L2-UX JS5-L2-UX Title of Job Sheet Diagnose Strut Suspension Systems Remove, Inspect, and Install Strut Assemblies Replace Strut Dampers, Springs, and Mounts Inspect and Replace Rear Leaf Springs Remove, Inspect, and Install Transverse Spring Systems Inspect and Replace Rear Coil Springs and Insulators Inspect and Replace Rear Suspension Control Arms and Bushings Inspect and Replace Rear Suspension Shock Absorbers Test Electronic Level Control Performance Leak Test an Electronic Level Control System Remove and Install an Electronic Level Control Compressor Test an Electronic Level Control Height Sensor Test and Diagnose Components of Electronically Controlled Suspension Systems Using a Scan Tool Service Nonsealed Tapered Roller Wheel Bearings Remove and Install Sealed Front-Wheel Bearings: Front-Wheel-Drive Vehicles Remove and Install Sealed Rear-Wheel Bearings: Front-Wheel-Drive Vehicles Remove, Inspect, and Install a Wheel Spindle/Knuckle Inspect and Inflate Tires Rotate Tires Dismount, Inspect, and Mount Tires Dismount, Inspect, and Mount a Tire on a Wheel Equipped With a Tire Pressure Sensor Repair Punctures in Tubeless Tires Inspect, Diagnose, and Calibrate a Tire Pressure Monitoring System Instructor Guide Page # 549552 553554 555558 589592 593594 595596 597600 601604 637638 639640 641642 643644 645646 Student Workbook Page # W 165168 W 169170 W 171174 W 175178 W 179-180 W 181182 W 183186 W 187190 W 193194 W 195196 W 197198 W 199200 W 201202 Date Instructors Initials
JS1-L2-UXI JS2-L2-UXI JS3-L2-UXI JS4-L2-UXI JS1-L1-UXIII JS2-L1-UXIII JS1-L2-UXIII JS2-L2-UXIII JS3-L2-UXIII JS4-L2-UXIII
679682 683684 685686 687688 751754 755756 771774 775778 779780 781782
W 205208 W 209210 W 211212 W 213214 W 219222 W 223224 W 225228 W 229232 W 233234 W 235236
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Job Sheet JS1-L4-UXIII JS2-L4-UXIII JS1-L1-UXIV JS1-L3-UXIV JS2-L3-UXIV JS3-L3-UXIV Title of Job Sheet Measure a Wheel-and-Tire Assembly for Radial and Lateral Runout Balance Wheel-and-Tire Assemblies Diagnose Various Steering, Suspension, and Wheel Alignment Concerns Measure and Correct Front-Wheel Alignment Measure and Correct Rear-Wheel Alignment Diagnose Alignment Concerns Caused by Damaged Components Instructor Guide Page # 799802 803804 831834 863866 867870 871876 Student Workbook Page # W 239242 W 243244 W 247250 W 253256 W 257260 W 261266 Date Instructors Initials
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AS1-L1-UI STEERING AND SUSPENSION SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. Which components in Rudolf Ackerman's steering system allowed the front wheels to turn in an arc?
NAME:
DATE:
2.
Which suspension system was superior to Ackerman's design in that it brought improved control and cushioned the vehicle against shocks?
3.
Which steering gear was introduced in the 1920s and is still used today.
4.
Are the steering system and suspension system closely related? Explain why or why not.
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5. What are the four basic rules of undercar service? A.
B.
C.
D.
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JS1-L2-UI COMPLETE A WORK ORDER WITH CONCERN, CAUSE, AND CORRECTION
Directions: 1. The instructor will list a repair. Complete the work order on the following page for the repair. To receive credit, all sections of the work order must be complete. Credit received for completing work order
NAME(S):
DATE:
EVALUATION
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Smiths Automotive Repair Customers Name: Address: Year/Make: Service Writer: Customer Authorization Signature: Customer Concern: Model: VIN: Technician: Date: Invoice #: Phone: Mileage:
Vehicle Service History Information:
Related Technical Service Bulletins:
Diagnostic Procedures Performed:
Cause:
Correction:
Labor Procedures and Costs
Estimated
Actual
Outside Labor Procedures and Costs
Total Labor Costs Parts Costs Quantity Part # Description
Total Parts Costs Labor Total Parts Total Sales Tax GRAND TOTAL
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JS2-L2-UI IDENTIFY AND INTERPRET A STEERING AND SUSPENSION CONCERN
Equipment: Personal protective equipment (PPE) Scan tool Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Identify the concern. If possible, ask the owner/driver the following questions. a. b. c. d. e. Under what conditions does the problem occur? Are there unusual sounds? Are there vibrations in the steering and suspension systems? Does the vehicle pull to one side or wander? How long has the problem existed? Is it getting worse?
4.
Test drive the vehicle under the conditions that the problem has been observed. CAUTION: Road test a vehicle only with the instructors approval. Before performing a road test, inspect the vehicle to ensure that the vehicle is safe and that a road test will not cause damage to the vehicle. Safety should be of prime importance during all road tests. Never drive in an unsafe manner in order to identify a problem. a. The road test should be performed by the individual who will perform the repairs.
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b. c. Ask the owner/driver to ride along during the road test. The owner/driver can assist in identifying the source of any problems. Record all abnormal conditions in the following space.
5.
Isolate the cause of the problem. a. Interpret vehicle and major component identification numbers. b. VIN Vehicle certification labels Calibration decals
Research applicable vehicle and service information. Steering and suspension components and their operation Vehicle service history Service precautions Technical service bulletins
c.
Perform a visual inspection of the steering and suspension system. Look for damaged or broken components. Look for worn or misaligned components. Check fluid levels. Inspect related electrical sensors, corrector, controls, and wiring.
d.
Connect a scan tool and check for stored diagnostic trouble codes (DTCs). Record information in the space below.
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e. 6. Test the systems and components that could cause the problem. Eliminate good components until the cause is found.
Determine the necessary action and record in the following space.
Average of the above evaluations
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AS1-L1-UII TYPES OF STEERING SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. Define the following terms. A. Conventional (linkage) steering system
NAME:
DATE:
B.
Power steering
C.
Rack-and-pinion steering system
D.
Steering column
E.
Steering gear
2.
What type of design is commonly used in manual steering gears?
3.
What is the function of the hydraulic power piston in an integrated power steering gear?
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4. When compared with the conventional steering system, what are two advantages of the rack-and-pinion steering system? A.
B.
5.
Which three linkage components in the conventional system are omitted in the rack-and-pinion system? A. B. C
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AS1-L2-UII CONVENTIONAL STEERING SYSTEM COMPONENTS
Directions Answer the following questions by writing all responses on this sheet. 1. Write the component name in the blank beside each function given. A. B. C. D. E. F. Supports the wheel bearing, hub, and wheel-and-tire assembly Transfers gearbox movement to the linkage Functions similar to a shock absorber Reduces effort required to turn steering wheel Used by driver to turn steering gear Connects the center link to the steering knuckle
NAME:
DATE:
2.
Explain how motion is transferred from the worm gear shaft to the sector gear shaft in a manual steering gear.
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3. Answer the following questions about the principles of hydraulics. A. According to Pascal's law, what happens to a confined liquid when it is put under pressure?
B.
Explain what occurs with regard to fluid motion and multiplying force when the input piston is smaller than the output piston.
C.
How does Pascals law apply to the power steering system?
4.
What are the three common types of power steering pumps? A. B. C.
5.
What is the function of the rotary valve in the rotary valve integrated power steering system?
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AS1-L3-UII RACK-AND-PINION STEERING SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. What does the rack in a manual rack-and-pinion steering system look like?
NAME:
DATE:
2.
In a manual rack-and-pinion system, what is the function of the bellows boots at the ends of the housing?
3.
What three components make up the typical power rack-and-pinion steering unit? A. B. C.
4.
How does the proportional rack-and-pinion steering system operate?
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5. Why is a vehicle with an EPS system able to provide steering assistance even if the engine is off?
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JS1-L4-UII INSPECT AND ADJUST MANUAL STEERING GEAR LUBRICANT LEVEL
Equipment: Hand tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for adjusting the steering gear lubricant level. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, B.)
Using the procedure, inspect and adjust the lubricant level in the steering gear. Determine and record the type of lubricant used. Record any leaks found in the steering gear.
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JS2-L4-UII INSPECT AND ADJUST POWER STEERING FLUID LEVELS
Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) Thermometer Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Determine and record the type of power steering fluid used.
4. 5.
Ensure that the engine is off, make sure the wheels are straight, and wipe away any dirt from around the dipstick. Remove the dipstick and determine the level, condition, and temperature of the fluid. Record observations.
6. 7.
Using the correct fluid, fill the system to the proper level. Replace the dipstick. Connect the exhaust ventilation equipment.
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CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed space. 8. 9. Start the engine. Let it idle while turning the steering wheel slowly from lock to lock two or three times. Shut off the engine. Disconnect the exhaust ventilation equipment. Repeat step 4 through step 8 to ensure that the fluid level is correct. Record observations in the following space.
NOTE: If the fluid is foamy, allow the vehicle to set a few minutes with the engine off so that the foam can dissipate. If foam is heavy, the vehicle may have to set for 1 hour. NOTE: If the dipstick has add and full marks instead of hot and cold full marks, maintain the fluid level between the add and full marks. If servicing an older system that does not use a dipstick, remove the reservoir cover or lid and adjust the fluid level to the reservoir's full mark. Average of the above evaluations
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JS3-L4-UII DIAGNOSE FLUID LEAKS IN THE POWER STEERING SYSTEM
DATE: NAME(S):
Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) Trouble light Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
Raise the vehicle's hood and visually inspect the steering system for leaks. a. b. If the steering system is saturated with fluid, thoroughly clean all suspected components. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. c. d. Start the engine and make three or four full lock-to-lock turns. Shut off the engine. Disconnect the exhaust ventilation equipment. Inspect the system for leaks. Record observations.
NOTE: In order to detect a slow leak, clean the steering system and drive the car for a distance before inspecting the system. NOTE: Hoses are usually not repairable; replace them.
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CAUTION: Do not attempt to substitute a fuel hose or any other type of hose for a power steering hose. Use only hoses that have been approved for power steering systems and that have the correct pressure rating. Most other hoses cannot withstand the extreme pressure demands of a power steering system. 4. Recommend steps to repair any leaks found in the steering system. Write the recommendations below.
5.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. Inspect the undercar portion of the steering system for leaks. Record observations below. Recommend steps to correct any leaks. Write recommendations below.
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AS1-L1-UIII STEERING GEAR CONCERNS
Directions Answer the following questions by writing all responses on this sheet. 1. What is the term for the condition in which the vehicle pulls in the direction of the drivers last steering maneuver after the steering wheel returns to the center?
NAME:
DATE:
2.
What is the term for a condition in which the rear tires lose traction before the front tires?
3.
Define the term steering play.
4.
Name four things to check when diagnosing steering gear operation in a road test. A.
B.
C.
D.
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5. List two factors that affect the effort required to turn the steering wheel. A. B.
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JS1-L1-UIII DIAGNOSE MANUAL AND POWER STEERING GEAR CONCERNS
Equipment: Exhaust ventilation equipment Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Connect the exhaust ventilation equipment. If inspecting a power steering system, start the vehicle's engine and run it at an idle. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area.
4.
Turn the steering wheel slowly from stop to stop. Respond to the questions below. a. Are there leaks in the system? (See JS3-L4-UII for a procedure to diagnose leaks in the power steering system.) Yes_____ No_____ b. c. d. e. Is there binding at any point? Is the same effort required to turn the steering wheel in both directions? Yes_____ No_____ Yes_____ No_____
Is excessive effort required to turn the wheel? Yes_____ No_____ Does the system make any unusual noises? Yes_____ No_____
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f. Does the steering wheel jerk during turns? (This question applies only to power steering vehicles.) Yes_____ No_____ 5. Record the possible causes of any of the problems noted in step 4.
6.
After obtaining permission from the instructor, drive the car slowly and carefully. Observe if the steering wheel returns properly from both left and right turns. Record observations. CAUTION: Road test a vehicle only with the instructor's approval.
7.
After obtaining permission from the instructor, drive the car at highway speed and respond to the following questions. a. b. Does the car pull to one side or the other? Does the car wander? Yes_____ No_____ Yes_____ No_____
8.
After obtaining permission from the instructor, drive the car slowly over bumps and rough pavement. Note any gear rattle or clunk. Record observations.
9. 10.
Shut off the engine. Disconnect the exhaust ventilation equipment. Record the possible causes of any of the problems noted in step 6 through step 8 above.
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JS1-L2-UIII REMOVE AND INSTALL A MANUAL STEERING GEAR
Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Using service information, locate a procedure for removing the manual steering gear from the vehicle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I.)
Using the above procedure, remove the steering gear from the vehicle. Record observations.
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5. Using the procedure outlined below, inspect the steering gear and related components. a. Inspect the gear mounting area of the vehicle frame for cracking or elongated holes. Repair a damaged frame-mounting area before reinstalling the gear. Record observations.
b.
Inspect the gear assembly for lubricant leaks or housing damage. Record observations.
c.
Inspect the flexible coupling. If the coupling is worn or damaged, replace it. Record observations.
6.
Using service information, locate a procedure for installing the vehicle's manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
NOTE: Be sure to check and adjust the steering gear lubricant level if necessary. Refer to JS1-L4-UII for this procedure. Using the procedure, install the vehicle's manual steering gear. Record observations.
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7. Check steering gear operation. Record observations.
8.
Lower the vehicle.
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JS2-L2-UIII DISASSEMBLE, CLEAN, AND INSPECT A MANUAL STEERING GEAR
DATE: NAME(S):
Equipment: Hand tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3. 4.
Remove the steering gear from the vehicle if required. Refer to JS1-L2-UIII for this procedure. Using service information, locate a procedure for disassembling the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, A.)
NOTE: After removing the gear, thoroughly clean its exterior with a safety solvent. NOTE: Carefully count the number of balls removed from the ball nut. Do not lose any of the balls. Using the procedure, disassemble the manual steering gear. Record observations.
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5. Using service information, locate a procedure for cleaning and inspecting the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, B.)
Using the procedure, clean and inspect the manual steering gear. Fill out the checklist below. If an item is marked "NOT OK," explain the problem in the space below and determine the necessary action to correct it. Worm Shaft Ball Nut Ball Nut Grooves Ball Guides Worm Bearings Gear Housing Sector shaft teeth Sector shaft fit Sector shaft bearing Steel Balls Lash Adjuster Screw OK OK OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
NOTE: Some worm adjuster bearings are not serviceable. Therefore, if a nonserviceable bearing is defective, replace the entire adjuster.
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JS3-L2-UIII REASSEMBLE AND ADJUST A MANUAL STEERING GEAR
DATE: NAME(S):
Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
Using service information, locate a procedure for reassembling the manual steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)
Using the procedure, reassemble the manual steering gear. Record observations below.
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4. Using service information, locate a procedure for adjusting the manual steering gear. Ensure that the procedure includes all necessary specifications. Make sure that the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)
Using the procedure, adjust the manual steering gear. Record observations below.
5.
Turn the worm shaft completely to the left and right several times. Note any binding or roughness. Record findings.
6.
Reinstall the steering gear on the vehicle. Refer to JS1-L2-UIII for this procedure.
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JS1-L3-UIII REMOVE AND INSTALL AN INTEGRATED POWER STEERING GEAR
Equipment: Drain pan Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Using service information, locate a procedure for removing the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)
Using the procedure, remove the power steering gear. Record observations below.
NOTE: Before removal, clean all dirt from around the fluid line connections at the steering gear.
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5. Using the procedure outlined below, inspect the gear assembly. a. Inspect the gear assembly for fluid leakage and housing damage. Record observations.
b.
Also inspect the gear mounting area of the vehicle frame for cracking or elongated holes. Record observations.
NOTE: Repair a damaged frame before reinstalling the steering gear. Consult the instructor for the proper procedure. c. Inspect the pressure and return hoses. Record observations.
d.
Inspect the flexible coupling for wear or damage. Record observations.
6.
Using service information, locate a procedure for installing the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the power steering gear. Record observations.
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7. After installation, perform the following tasks. a. b. c. Be sure to replace all defective parts. Fill the steering reservoir and bleed the system. Inspect for leaks and repair any leaks found. Record observations.
d. e.
Lower the vehicle. Check the operation of the steering gear. Record observations.
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JS2-L3-UIII DISASSEMBLE, CLEAN, AND INSPECT AN INTEGRATED POWER STEERING GEAR
Equipment: Drain pan Hand tools Personal protective equipment (PPE) Various specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3. 4.
Remove the steering gear from the vehicle, if required. Refer to JS1-L3-UIII for this procedure. Using service information, locate a procedure for disassembling the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, AC.)
NOTE: Before disassembling the power steering gear, plug the fluid ports and thoroughly clean the gear's exterior with a safety solvent. NOTE: Some manufacturers do not service certain steering gear components and do not recommend disassembling the steering gear. Closely follow the manufacturer's directions for the vehicle.
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Using the procedure, disassemble the power steering gear. Record observations below.
5.
Using service information, locate a procedure for cleaning and inspecting the vehicle's power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, D.)
Using the procedure, clean and inspect the vehicle's power steering gear. Use the checklist below to determine if the components are defective. NOTE: Thoroughly clean all parts in a clean safety solvent and blow-dry. Control Valve Assembly Piston Nut Worm Shaft Stub Shaft Sector Shaft Bushings Thrust Bearings Gear Housing Inlet Check Valve Steel Balls Ball Guides OK OK OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
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If any of the components in the list are marked "Not OK," determine the necessary action and record below.
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JS3-L3-UIII REASSEMBLE AND ADJUST AN INTEGRATED POWER STEERING GEAR
Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Various specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME)(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for reassembling the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, reassemble the steering gear. Record observations.
NOTE: Be sure to replace all damaged or missing steering gear parts according to the instructor's directions. NOTE: During assembly, lightly coat all components with the appropriate power steering fluid.
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4. Using service information, locate a procedure for adjusting the power steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV.)
Using the procedure, adjust the power steering gear. Record observations.
5.
Turn the worm shaft completely to the left and right several times. Note any binding or roughness. Record observations.
6.
Reinstall the steering gear on the vehicle if required. Refer to JS1-L3-UIII for this procedure.
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JS1-L4-UIII INSPECT AND REPLACE A PITMAN ARM
Equipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Pitman arm puller Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting the vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Inspect the pitman arm for wear or damage. Record observations in the space below.
5.
Using the procedure outlined below, remove and inspect the pitman arm. a. b. c. Place a mark on the sector shaft and pitman arm to aid in positioning the components during reassembly. Remove the cotter pin from the castellated nut that connects the pitman arm to the steering linkage. Using a taper-breaking tool, separate the pitman arm from the steering linkage.
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d. e. 6. Remove the nut and lockwasher from the sector shaft. Using the pitman arm puller, remove the pitman arm from the steering sector shaft using the pitman arm puller.
Inspect the tapered hole and stud in the pitman arm and steering link. Replace any worn parts. Record observations in the space below.
7.
Using the procedure outlined below, install the pitman arm. a. Refer to the appropriate service information for torque specifications. Record the specifications below. Pitman Arm to Sector Shaft Pitman Arm to Steering Link b. ____________ ____________
Place the wheels in the straight-ahead position and center the steering wheel. Install the pitman arm on the sector shaft. Use the marks made before disassembly to position the guide properly. NOTE: If the pitman arm has a master spline, make sure the arm aligns with it.
c. d.
Install the lockwasher and nut on the sector shaft and torque to specifications. Connect the pitman arm to the steering linkage. Tighten the castellated nut to the specified torque. Continue to tighten the nut until the cotter pin can be inserted. CAUTION: If the opening in the castellated nut does not align with the hole in the stud, continue to tighten the nut to the next opening and insert the cotter pin. Never loosen a nut to align openings; doing so can result in steering system failure.
e. f.
If the ball socket construction provides a lubrication fitting or plug, lubricate the socket with an EP-type chassis lubricant. If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace them with new nuts of the identical design.
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g. Turn the wheels through a full left and right turn to check for smooth operation. Record observations in the space below.
8.
Lower the vehicle.
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JS2-L4-UIII INSPECT AND REPLACE A CENTER LINK
DATE: NAME(S):
Equipment: Ball stud taper-breaking tool Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, be sure to use proper lifting equipment and observe all safety precautions.
4.
Inspect the center link for wear or damage. Record observations in the space below.
5.
Using the procedure outlined below, remove and inspect the center link. a. b. Remove cotter pins and castellated nuts from all four connecting points. Using a taper-breaking tool, separate the center link from the pitman arm, idler arm, and the tie-rods.
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6. Inspect the tapered studs and mounting holes of the center link and all connecting arms. Clean excessive grease and dirt from all parts. Replace worn parts. Record observations.
7.
Using the procedure outlined below, install the center link. a. Refer to the appropriate service information for the torque specifications. Record the specifications below. Pitman Arm to Center Link Idler Arm to Center Link Tie-Rods to Center Link b. ____________ ____________ ____________
Install the center link, tighten the connecting nuts to the specified torque, and install the cotter pins. NOTE: If an opening in a castellated nut does not align with the hole in the stud, continue to tighten the nut to the next opening and insert the cotter pin. Never loosen the nut to align openings.
c. d. e.
If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace with new ones of the same design. Lubricate all ball sockets on the center link with an EP-type chassis lubricant if possible. Turn the wheels through a full left turn and right turn to check for smooth operation. Record observations.
f. g.
Lower the vehicle. Check the toe and adjust as necessary. See the instructor for this procedure.
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JS3-L4-UIII INSPECT AND REPLACE TIE-ROD ENDS
EVALUATION NAME(S):
DATE:
3.
4.
Inspect the tie-rod assembly for wear or damage. Record findings.
5.
Using the procedure outlined below, remove and inspect the tie-rod end. a. Loosen the tie-rod sleeve clamp bolt on the tie-rod end that is being removed. NOTE: If the clamp bolt and the sleeve are rusty, spray them with penetrating oil before disassembly. b. Measure the distance from the edge of the tie-rod sleeve to the center of the tie-rod end socket. Record this measurement below for use during reassembly. Measurement ______________________________
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c. d. Remove the cotter pin and castellated nut from the ball stud. Using a taper-breaking tool, separate the tie-rod from the center link or steering knuckle. CAUTION: Using a pickle fork to break the taper may destroy the ball socket. f. Thread the tie-rod end out of the adjusting sleeve. Count the number of turns required to remove the tie-rod end. Record the number below. Turns Required 6. ____________________________
Inspect the tie-rod sleeve for damage, distortion, bad threads, or severe rusting. If any of the above problems are found, replace the sleeve. Observe the condition of the sleeve. Record observations. Using the procedure outlined below, install the tie-rod end. a. Refer to the appropriate service information for the torque specifications. Record the specifications. Outer Tie-Rod to Steering Knuckle Inner Tie-Rod to Center Link Adjuster Sleeve Clamp Bolt b. _________ _________ _________
7.
Thread the tie-rod end into the sleeve and count the number of turns. Stop when the tie-rod end turns the same amount of times as recorded in step 5f. Repeat the measurement made in step 5b. If necessary, adjust the tie-rod in or out to match the previous measurement. Connect the tie-rod to the steering knuckle, tighten the nut to specified torque, and install the cotter pin. If the vehicle uses self-locking nuts instead of castellated nuts, discard the old nuts and replace them with new nuts of the identical design. Center both the inner and outer tie-rod ends in their sockets and tighten the clamp bolts to the specified torque.
c. d. e.
f.
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g. h. i. j. If the ball socket construction provides a lubrication fitting or plug, lubricate the socket with an EP-type chassis lubricant. Turn the wheels through a full left turn and full right turn to check for smooth operation. Check the toe and adjust as necessary. See the instructor for this procedure. Lower the vehicle.
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JS4-L4-UIII INSPECT AND REPLACE AN IDLER ARM
EVALUATION NAME(S):
DATE:
3.
4.
Using service information, locate a procedure for inspecting the vehicle's idler arm. Include any specific tolerances for idler arm wear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, inspect the idler arm for wear or damage. Record observations.
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5. Using service information, locate a procedure for removing and installing the idler arm in the vehicle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VIII.)
Using the procedure, remove and install the idler arm. Record observations.
NOTE: After removing the idler arm, inspect the stud or mounting hole in the center link. If the hole is worn, replace the center link. Average of the above evaluations
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JS5-L4-UIII INSPECT AND REPLACE A STEERING DAMPER
EVALUATION NAME(S):
DATE:
3.
4.
Inspect the steering damper for damage and leakage. Also make sure the damper is mounted securely. Record observations in the space below.
5.
Disconnect one end of the damper. Extend and compress the damper and note any problems. Answer the following questions. Is there tightness or binding during damper travel? Yes _______ No _________
Is there fluid leakage during damper travel? Yes _______ No _________
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Is there skipping (lack of resistance) during damper travel? Yes _______ No _________
NOTE: If "Yes" is the answer to any of the above questions, replace the damper. 6. Disconnect both the frame and the linkage ends and remove the damper from the vehicle. Inspect all mounting brackets and grommets. Replace any broken or deteriorated hardware. Using the procedure outlined below, install a steering damper. a. Refer to the appropriate service information for torque specifications. Record specifications. Frame End Linkage End b. ______________ ____________
7.
Install the damper to the vehicle's frame and to the steering linkage. Tighten fasteners to the specified torque. Install new cotter pins where used. Turn the wheels through a full left turn and full right turn. Make sure the wheels turn smoothly. Record observations in the space below.
c.
8.
Lower the vehicle.
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JS1-L1-UIV REMOVE AND INSTALL A MANUAL RACK-AND-PINION STEERING GEAR
NAME(S):
DATE:
EVALUATION
3.
When necessary, use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Using service information, locate a procedure for removing the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, A.)
Using the procedure, remove the manual rack-and-pinion steering gear. 5. Inspect the gear assembly for lubricant leaks or housing damage. Record observations.
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6. Inspect the condition of the flexible coupling and rubber mounting bushings. Replace any worn or deteriorated parts. Record observations.
7.
Using service information, locate a procedure for reinstalling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, B.)
Using the procedure, reinstall the manual rack-and-pinion steering gear. 8. Check the operation of the steering system. Record observations.
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JS2-L1-UIV INSPECT AND REPLACE RACK-AND-PINION INNER TIE-RODS AND BELLOWS BOOTS
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using the procedure outlined below, inspect the condition of the inner tie-rods and bellows boots. a. b. Squeeze the boot until the inner socket is felt. While squeezing the boot, have an assistant perform one of the following steps. 1. 2. c. Turn the steering wheel back and forth one-eighth to one-quarter of a turn. Push and pull on the tires and turn them in and out one-quarter of a turn. If the tie-rod feels loose, replace it.
To inspect hard plastic rod boots, perform the following steps. Lock the steering wheel and use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
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With the vehicle off the ground, turn the wheels in and out while watching for movement in the tie-rods. If movement is detected, replace the tie-rods.
d.
Record observations and describe any repairs in the space below.
e.
If a more thorough inspection is necessary, perform the steps below. Remove the inner tie-rod boot clamps and slide the boot back to expose the rod. Turn the steering wheel back and forth while the wheels rest on the ground. Watch the sockets for movement. If movement is detected, replace the rod. Record observations and describe any repairs in the space below.
4.
Using service information, locate a procedure for removing the rack-and-pinion inner tie-rods. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, B.)
Using the procedure, remove the rack-and-pinion inner tie-rods. Record observations.
NOTE: It may be necessary to remove the rack-and-pinion unit before removing the inner tie-rod and bellows. If so, refer to JS1-L1-UIV for the procedure.
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NOTE: Some manual steering gears are filled with a liquid lubricant that may spill when removing the boot. When checking inner tie-rods on manual rack-and-pinion systems that contain a liquid lubricant, do not remove the boot unless removing the entire assembly or replacing the lubricant. 5. Using service information, locate a procedure for reinstalling the rack-and-pinion inner tie-rods. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, G.)
Using the procedure, reinstall the rack-and-pinion inner tie-rods. 6. Check the operation of the steering system. Record observations.
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JS3-L1-UIV DISASSEMBLE, CLEAN, AND INSPECT A MANUAL RACK-ANDPINION STEERING GEAR
Equipment: Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3. 4.
Remove the steering gear from the vehicle, if required. Refer to JS1-L1-UIV for this procedure. Using service information, locate a procedure for disassembling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)
Using the procedure, disassemble the manual rack-and-pinion steering gear. Record observations.
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5. 6. Thoroughly clean all parts in a safety solvent and then blow-dry the parts. Inspect the parts and use the checklist below to identify any defective components. Gear housing Pinion Rack Pinion bearings Rack bearing Bellows boots Rack bushings Yoke spring OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
Determine the necessary action for correcting any problems identified in the above chart and record below.
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JS4-L1-UIV REASSEMBLE AND ADJUST A MANUAL RACK-AND-PINION STEERING GEAR
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for reassembling the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV.)
Using the procedure, reassemble the manual rack-and-pinion steering gear. Record observations.
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4. Using service information, locate a procedure for adjusting the manual rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Submit the procedure to the instructor. Have the instructor check the box to approve the procedure.
Using the procedure, adjust the manual rack-and-pinion steering gear. Record observations.
5.
Turn the pinion shaft through a couple of full left to right turns. Note any binding or roughness. Record observations.
6.
Reinstall the steering gear on the vehicle, if required. For this procedure, refer to JS1-L1-UIV.
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JS1-L2-UIV REMOVE AND INSTALL A POWER RACK-AND-PINION STEERING GEAR
Equipment: Drain pan Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Using service information, locate a procedure for removing the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)
Using the procedure, remove the power rack-and-pinion steering gear. Record observations below.
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5. Using service information, locate a procedure for installing the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, B.)
Using the procedure, install the power rack-and-pinion steering gear. 6. Check operation of the power steering system. Record observations below.
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JS2-L2-UIV DISASSEMBLE, CLEAN, AND INSPECT A POWER RACK-ANDPINION STEERING GEAR
Equipment: Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3. 4.
Remove the steering gear from the vehicle, if required. For this procedure, refer to JS1-L2-UIV. Using service information, locate a procedure for disassembling the power rack-and-pinion steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II.)
Using the procedure, disassemble the power rack-and-pinion steering gear. Record observations below.
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5. 6. Thoroughly clean all parts with a safety solvent and blow-dry them. Use the following checklist to identify any defective components found during the inspection. Add components to the list if necessary. Gear Housing Rack Pinion and Control Valve Assembly Pinion Bearings Rack Bearing Bulkhead Seals Rack Bushings OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
NOTE: Except for the sealing rings on the spool valve, service the valve and pinion assembly as a complete unit. Determine necessary action for correcting any problems identified in the above checklist and record below.
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JS3-L2-UIV REASSEMBLE AND ADJUST A POWER RACK-AND-PINION STEERING GEAR
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise or holding fixture Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for reassembling the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III.)
Using the procedure, reassemble the steering gear. Record observations below.
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4. Using service information, locate a procedure for adjusting the steering gear. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, adjust the steering gear. Record observations.
5.
Turn the pinion through several complete left-to-right turns. Note any binding or roughness. Record observations.
6.
Reinstall the rack-and-pinion steering gear on the vehicle if required. For this procedure, refer to JS1-L2-UIV.
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JS4-L2-UIV TEST AND DIAGNOSE COMPONENTS OF ELECTRONICALLY CONTROLLED STEERING SYSTEMS USING A SCAN TOOL
Equipment: EPS-capable scan tool Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Question the customer about the conditions when the problem occurred in order to reproduce the same condition for troubleshooting. Find out when the electric power-assist steering (EPS) indicator came on, such as while turning, when the vehicle was at a certain speed, on start-up, etc. Record the findings below.
4. 5. 6.
Locate the correct scan tool and software. With the ignition switch off, connect the scan tool to the data link connector (DLC). Turn the ignition to the run position and use the scan tool to retrieve the diagnostic trouble codes (DTCs)OBD I (on-board diagnostics generation I) and OBD II (on-board diagnostics generation II). Interpret the trouble codes. Record observations below.
7.
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8. 9. 10. Perform a pinpoint test to locate the faults. Clear the codes. Perform the necessary procedures to correct the problem. Record below.
11.
After obtaining permission from the instructor, test drive the vehicle to ensure proper EPS operation. CAUTION: Road test a vehicle only with the instructor's approval.
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JS5-L2-UIV INSPECT AND TEST NONHYDRAULIC ELECTRIC POWER-ASSIST STEERING
Equipment: Digital multimeter (DMM) Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3. 4.
Use service information to locate the electric power-assist steering (EPS) components. Using service information, locate a procedure for inspecting and testing the EPS control unit. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, B.)
Using the procedure, inspect and test the control unit. Record observations below.
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5. Using service information, locate a procedure for inspecting and testing the EPS rack-and-pinion motor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, C.)
Using the procedure, inspect and test the rack-and-pinion motor. Record observations below.
6.
Using service information, locate a procedure for inspecting and testing the EPS pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, D.)
Using the procedure, inspect and test the pressure sensor. Record observations below.
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JS1-L3-UIV REPLACE RACK BOOTS (END TAKE-OFF UNITS)
Equipment: Caliper Hand tools Personal protective equipment (PPE) Tie-rod puller Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Using service information, locate a procedure and specification for performing rack boot replacement. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I.)
Using the procedure, replace the rack boots. Record observations.
4.
Check the wheel alignment and adjust if necessary.
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W 78

JS2-L3-UIV REPLACE RACK MOUNT BUSHINGS
DATE: NAME(S):
EVALUATION
3.
Using service information, locate a procedure and specifications for performing rack mount bushing replacement. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II.)
Using the procedure, replace the rack mount bushings on both sides of the vehicle. Record observations in the space provided.
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JS1-L1-UV TEST POWER STEERING SYSTEM PRESSURE
Equipment: Adapter hose and fittings Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Safety valve Shutoff valve 0 psi to 2,000 psi pressure gauge Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Using service information, locate a procedure for connecting power steering pressure testing equipment to the vehicle. The procedure must also list all pressure specifications and describe which type of power steering fluid the vehicle needs. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, draw a diagram in the space below of how the equipment should be connected.
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4. Using the diagram, connect a pressure gauge and shutoff valve to the outlet side of the pump. Completely open the shutoff valve. NOTE: Be sure to clean around the fittings before removing them; doing so prevents fluid contamination. 5. 6. Fill the pump reservoir with the correct fluid and bleed the system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use the approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 7. 8. Start the engine and allow it to idle. With the tester valve still open, operate the engine at idle speed and read the gauge. The reading indicates the pump flow pressure. Be sure that the reading is within the specifications determined in step 3 of this job sheet. Record the pressure below. _______ psi 9. Check the pump's relief pressure. a. Close the test valve completely and then reopen it three times. Record the pressure each time the test valve opens and closes. CAUTION: Do not hold the valve closed for more than 5 seconds; doing so could damage the pump. 1. _______ psi 2. _______ psi 3. _______ psi b. Compare the readings to manufacturer's specifications and record observations below.
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10. Check the condition of the steering gear, power cylinder and control valve, and hydro-boost valve. a. Turn the steering wheel to the left and right stops and record the highest pressure. Left Stop __________ psi Right Stop __________ psi b. Compare these readings with the maximum pump output and record observations below.
11.
If the vehicle is equipped with hydro-boost brakes and does not pass the test under step 10, bypass the hydro-boost unit to isolate the cause of the problem. Record observations below. CAUTION: The vehicle does not have power-assisted brakes while the hydro-boost is bypassed.
12. 13. 14. 15.
Disconnect the pressure test equipment from the vehicle. Fill the power steering reservoir with the correct fluid and bleed the system. Shut off the engine. Disconnect the exhaust ventilation equipment. Using the results of the above tests, describe the condition of the power steering system below. If there are any problems during the test, determine necessary action.
Average of above evaluations
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JS1-L2-UV REMOVE AND INSTALL A POWER STEERING PUMP
DATE: NAME(S):
Equipment: Belt tension gauge Drain pan Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Vise Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
Using service information, locate a procedure for removing the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)
Using the procedure, remove the power steering pump. Record observations.
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4. 5. Drain the fluid from the reservoir, if necessary, and clean the exterior of the pump with safety solvent. Inspect the power steering pump and mountings. Use the following checklist to indicate problems with the pump. Pulley Reservoir Mountings Hoses Drive Belt OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK
Determine the necessary action for any item marked "Not OK" and record below.
NOTE: Replacement pumps generally are not equipped with a pulley. Remove the old pulley and install it on the new pump. Inspect the old pulley carefully. NOTE: Replacement pumps may or may not be equipped with a reservoir. Before installing an old reservoir on a new pump, make sure the reservoir is in good condition. 6. If necessary, replace the pulley that drives the new pump. a. Remove the pulley. Install a suitable pulley removal tool on the pulley hub. Place the removal tool in a bench vise with the pump pointing upward. Hold the pump and rotate the removal tool nut counterclockwise to remove the pulley. CAUTION: Do not apply inward or outward pressure on the pulley shaft to remove or install the pulley; doing so causes damage to the internal pump.
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b. Install the new pulley. 7. Place the pulley against the pump shaft. Screw the installation tool into the threaded hole in the pump shaft. Place the end of the tool in the vise with the pump extending upward. Hold the pump and turn the tool nut to install the pulley on the pump shaft.
Using the procedure outlined below, replace the reservoir, if necessary. a. Remove the reservoir. Support the pump housing securely in a vise or holding fixture. Remove the outlet fitting and O-ring. Remove any other retaining bolts. Using a wood block and a hammer (or a soft-faced hammer), tap around the flange of the reservoir to release it from the pump. CAUTION: Never tap around the flange with a steel hammer or pry directly on the reservoir. b. Remove and discard the pump to reservoir O-ring. Thoroughly clean the reservoir in a safety solvent and blowdry.
Install the new reservoir. Install a new reservoir O-ring seal and outlet fitting gasket on the pump housing. Coat the inside edge of the reservoir and the O-ring with petroleum jelly. Place the reservoir over the pump housing and carefully align all holes. Use a hammer and a block of wood to tap the reservoir into place.
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8. Install all retainers and tighten them to the specified torque. Using service information, locate a procedure for installing the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, E.)
Using the procedure, install the power steering pump. 9. Using service information, locate a procedure for adjusting the power steering belt. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, F.)
Using the procedure, adjust the power steering belt. 10. 11. Fill the power steering reservoir with the correct fluid and bleed the system. Inspect for and correct any leaks.
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JS2-L2-UV INSPECT AND REPLACE POWER STEERING PRESSURE HOSES
DATE: NAME(S):
EVALUATION
3.
4.
Inspect the power steering hoses. Use the following checklist to indicate problems with the hoses. Dampness and leakage at crimp joints Abnormal swelling Abrasions Cracks Soft or spongy feel Damaged or worn fittings Yes Yes Yes Yes Yes Yes No No No No No No
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Determine the necessary action for any item marked "Yes" and record below.
5.
Using service information, locate a procedure for removing the power steering pressure hoses. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, remove the power steering hose. Record observations below.
6.
Using service information, locate a procedure for installing the power steering pressure hoses. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the power steering hose. Record observations.
7. 8. 9.
Fill the reservoir with the specified fluid and bleed the system. Check for and repair any leaks. Flush the power system gear and pump. See JS5-L2-UV and JS6-L2-UV.
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JS3-L2-UV SERVICE A POWER STEERING PUMP
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3. 4.
If required, remove the pump from the vehicle. Refer to JS1-L2-UV for this procedure. Using service information, locate a procedure for disassembling the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, A.)
Using the procedure, disassemble the power steering pump. Record observations.
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5. Thoroughly clean all the steering pump components in a safety solvent and blow-dry. Inspect the components. Use the chart below to indicate any problems with the components. Housing Rotor Shaft and bearings Reservoir Pulley Pressure Plate Thrust Plate Vanes Cam Ring OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
6.
Using service information, locate a procedure for reassembling the power steering pump. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, C.)
Using the procedure, reassemble the power steering pump. Record observations.
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7. After assembly, manually rotate the shaft and check the pump for binding. The shaft should rotate freely. Some manufacturers give a turning torque specification for shaft rotation. Reinstall the power steering pump on the vehicle, if required. For this procedure, refer to JS1-L2-UV.
8.
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JS4-L2-UV INSPECT, REPLACE, AND ADJUST THE POWER STEERING PUMP BELT
Equipment: Belt tension gauge Hand tools Personal protective equipment (PPE) Torque wrench Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Inspect the power steering pump belt. Use the list of defects below to indicate problems with the power steering belt. Replace the belt if it is defective. Glazed Cracked Oil soaked Torn or split Improper alignment Yes Yes Yes Yes Yes No No No No No
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4. Using service information, locate a procedure for removing, installing, and adjusting the power steering pump belt. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, remove and install the belt. 5. Using the procedure from step 4 above, adjust the power steering belt tension, if necessary. (For a general procedure, see Section I, F.)
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JS5-L2-UV FLUSH THE POWER STEERING GEAR
Equipment: Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper equipment and observe all safety precautions. lifting
4. 5. 6.
Disconnect the return hose from the power steering pump. Place the pump end of the hose in a drain pan. Disable the ignition system so the vehicle cannot start. For the procedures to disable the ignition system, refer to specific service information. Fill the fluid reservoir with clean fluid to the specified full mark. With the ignition system disabled, crank the engine and turn the wheel from lock to lock. Have an assistant continue to add fluid until about 2 quarts push through the system. CAUTION: Do not crank the starter for more than 30 seconds at a time. Pause and let the starter cool between cranks. Exceeding 30second cranks could damage the starter.
7. 8.
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CAUTION: Do not let the power steering pump run dry. 9. 10. 11. 12. 13. 14. 15. Reconnect the return hose to the power steering pump. Fill the fluid reservoir with clean fluid to the specified full mark. Crank the engine and turn the wheels from lock to lock to force air out of the system. Recheck the fluid level and add fluid if necessary. Lower the vehicle. Reconnect the ignition system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 16. 17. 18. 19. Start the engine and turn the wheel from lock to lock to remove any remaining air in the system. After the engine reaches normal operating temperature, recheck the fluid and add fluid if necessary. Lower the vehicle. Shut off the engine. Disconnect the exhaust ventilation equipment.
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JS6-L2-UV FLUSH THE POWER STEERING PUMP
Equipment: Drain pan Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4. 5. 6. 7. 8.
Disconnect the gear end of the pressure hose. Place the gear end of the pressure hose in a drain pan. Disable the ignition system so the vehicle cannot start. For procedures to disable the ignition system, refer to specific service information. Fill the fluid reservoir with clean fluid to the specified full mark. With the ignition system disabled, crank the engine and turn the wheel from lock to lock. Have an assistant continue to add fluid until about 2 quarts push through the system. CAUTION: Do not crank the starter for more than 30 seconds at a time. Pause and let the starter cool between cranks. Exceeding 30second cranks could damage the starter. CAUTION: Do not let the power steering pump run dry.
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9. 10. 11. 12. 13. 14. 15. Reconnect the pressure hose to the steering gear. Fill the fluid reservoir with clean fluid to the specified full mark. Crank the engine and turn the wheels from lock to lock to force the air out of the system. Recheck the fluid level and add fluid if necessary. Lower the vehicle. Reconnect the ignition system. Connect the exhaust ventilation equipment. CAUTION: Be sure to use approved exhaust ventilation equipment when operating a vehicle in an enclosed area. 16. 17. 18. 19. Start the engine and turn the wheel from lock to lock to remove any remaining air in the system. After the engine reaches normal operating temperature, recheck the fluid and add fluid if necessary. Lower the vehicle. Shut off the engine. Disconnect the exhaust ventilation equipment.
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JS7-L2-UV IDENTIFY HYBRID VEHICLE POWER STEERING SYSTEM ELECTRICAL CIRCUITS SERVICE AND SAFETY PRECAUTIONS
Equipment: Personal protective equipment (PPE) Safety cones for the work area Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the space provided.
NAME(S):
DATE:
EVALUATION
3.
Using service information, determine the locations of the high-voltage system components, including the high-voltage cables and service plug. Record in the space provided.
4.
Using service information, determine if special care is needed when handling any components of the high-voltage system. Record in the space provided.
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5. Using service information, locate a procedure for deactivating the high-voltage system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see section V, D.)
Using the procedure, deactivate the high-voltage system.
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AS1-L1-UVI ENERGY-ABSORBING STEERING COLUMNS
Directions Answer the following questions by writing all responses on this sheet. 1. What holds the steering wheel to the steering shaft.
NAME:
DATE:
2.
Why does the government require all vehicles to be equipped with an energy-absorbing steering column?
3.
Explain the design of the two-piece steering column and how it operates during a collision.
4.
What are the four principle components of the energy-absorbing steering column? A. B. C. D.
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5. What is the purpose of the breakaway capsules in the column mounting bracket?
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AS1-L2-UVI AIR BAG SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. Provide two different names for air bag systems. A. B. 2. Where is the driver-side air bag located?
NAME:
DATE:
3.
Air bags are passive restraints. What does that statement mean?
4.
Are air bags alone adequate protection during a collision? Explain why or why not.
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5. Write the air bag component name in the blank beside each description given. A. B. C. D. E. Contains bag as well as chemical that inflates the bag Lets the driver know if the system is functioning properly Types include mass, roller, and accelerometers Computer that stores electronic diagnostic codes Provides air bag electrical connection between the steering wheel and steering column Holds the air bag system wires
F.
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JS1-L3-UVI IDENTIFY VEHICLES EQUIPPED WITH A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Equipment: Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
In the space below, record the digits in the vehicle identification number that indicate if the vehicle is equipped with an SRS.
4.
In the space below, record any other indicators such as symbols on the vehicle or warning schematics that indicate if the vehicle is equipped with an SRS.
NOTE: An oversized steering wheel hub is not sufficient evidence that the vehicle is equipped with an SRS. Average of the above evaluations
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JS2-L3-UVI DISABLE AND ENABLE A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a schematic and procedure for disabling an air bag system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, B.)
Using the procedure, disable the air bag system. CAUTION: After removing the negative battery cable, tape it to ensure that it does not contact the battery. CAUTION: After completing the deployment procedure, wait until the reserve power is depleted before attempting further service. The depletion time required for the reserve power varies greatly depending on the vehicle. Obtain the exact depletion time from the manufacturer's service information.
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5. Using service information, locate a procedure for enabling the air bag. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, enable the air bag. Average of the above evaluations
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JS3-L3-UVI REMOVE AND INSTALL A STEERING WHEEL ON A VEHICLE WITH A SUPPLEMENTAL RESTRAINT SYSTEM (SRS)
Equipment: Personal protective equipment (PPE) Hand tools Steering wheel puller Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for removing a steering wheel on a vehicle equipped with a supplemental restraint system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, A.)
Using the procedure, remove the steering wheel. Record observations below.
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4. Using service information, locate a procedure for installing a steering wheel on a vehicle equipped with a supplemental restraint system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, B.)
Using the procedure, install the steering wheel. Record observations below.
5.
Verify that the steering system is operating properly and the air bag system circuit is active.
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JS4-L3-UVI DIAGNOSE STEERING COLUMN CONCERNS AND REMOVE AND INSTALL AN ENERGY-ABSORBING STEERING COLUMN
Equipment: Exhaust ventilation equipment Hand tools Personal protective equipment (PPE) Steering wheel puller Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Inspect the operation of the steering column. Answer the following questions. In the space below the questions, determine necessary action to correct any problems found during the inspection. a. Does the steering wheel lock correctly? Yes_____ No_____
b.
Does the ignition switch operate correctly? Yes_____ No_____
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c. Is the amount of effort required to turn the steering wheel appropriate? (If the vehicle has power steering, start the engine before performing this test.) Yes_____ No_____
d.
Are there any unusual noises when the steering wheel is turned? (If the vehicle has power steering, start the engine before performing this test.) Yes_____ No_____
e.
Does the column shift lever operate correctly? (This question applies only to vehicles equipped with column shifters.) Yes_____ No_____
f.
Does the tilt mechanism operate correctly? (This question applies only to vehicles equipped with a tilt mechanism.) Yes_____ No_____
g.
Does the column seem to be loose while the steering wheel is turning? Yes_____ No_____
4.
Using service information, locate a procedure for removing the steering column. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, A.)
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Using the procedure, remove the steering column. Record observations.
CAUTION: Never remove a steering wheel by hitting the end of the steering shaft with a hammer; doing so may damage the energyabsorbing column. CAUTION: Handle the steering column carefully after removing it because it is extremely susceptible to damage. Dropping the column on its end could collapse the steering shaft or loosen the plastic injections. 5. Inspect the column assembly. Answer the questions below. In the space after the questions, determine necessary actions to correct any problems found during the inspection. a. Does the flexible coupling show signs of wear? Yes_____ No_____
b.
Do the column mountings show signs of looseness or cracking? Yes_____ No_____
c.
Are there any loose grommets on the shift linkage? Yes_____ No_____
6.
Using service information, locate a procedure for installing the steering column. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, C.)
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Using the procedure, install the steering column. Record observations.
CAUTION: Failing to tighten bolts to the specified torque or installing bolts that are too long could render an energy-absorbing steering column ineffective. 7. After obtaining the instructor's permission, test drive the vehicle to check the operation of the column as outlined below. CAUTION: Road test a vehicle only with instructor's permission. a. Put the gear shift in all positions and watch for any problems in the column. Record observations.
b.
Watch for any problems in the steering column while turning the steering wheel through left turns and right turns. Record observations.
c.
Check the operation of all electrical devices in the steering column. Record observations.
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JS5-L3-UVI DISASSEMBLE, INSPECT, AND REASSEMBLE AN ENERGYABSORBING STEERING COLUMN
Equipment: Hand tools Personal protective equipment (PPE) Specialty tools Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3. 4.
If required, remove the steering column from the vehicle. Refer to JS4-L3-UVI for this procedure. Using service information, locate a procedure for disassembling the steering column. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, A.)
Using the procedure, disassemble the steering column. Record observations.
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5. Inspect the steering column. Use the following checklist to indicate problems with steering column components. Steering wheel Steering shaft universal joints Flexible couplings Collapsible column Lock cylinder mechanism Mast jacket Steering shaft Shift tube Shift bowl Steering shaft bearings Wheel lock mechanism Tilt mechanism OK OK OK OK OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
Determine necessary action for any components marked "Not OK" and record below.
6.
Visually inspect the air bag system. a. In the spaces provided, list the major components inspected and indicate if there are any problems. NOTE: If there is not enough space provided, list additional components on another sheet of paper. NOTE: Terminology used to describe air bag components may vary depending on the vehicle. When listing components, use the same terminology as the manufacturer.
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Component Name Problem Detected
Component Name
Problem Detected
Component Name
Problem Detected
Component Name
Problem Detected
7.
Using service information, locate a procedure for assembling the steering column. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, C.)
Using the procedure, assemble the steering column. Record observations.
8.
Reinstall the steering column in the vehicle, if required. Refer to JS4-L3-UVI for this procedure.
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AS1-L1-UVII SUSPENSION SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. List three functions of a suspension system. A.
NAME:
DATE:
B.
C.
2.
Describe the movement of the coil springs and tires in the following positions. A. Jounce position
B.
Rebound position
3.
Which vehicle components are considered unsprung weight?
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4. Describe the following frame designs. A. Conventional
B.
Unibody
5.
Why does an independent suspension system provide a smoother ride than a nonindependent suspension system?
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AS1-L2-UVII FRONT SUSPENSION TYPES AND COMPONENTS
Directions Answer the following questions by writing all responses on this sheet. 1. Which type of suspension incorporates a coil spring and shock absorber in a single unit.
NAME:
DATE:
2.
Which type of suspension uses upper and lower control arms of different lengths.
3.
What are the three most common types of springs used on suspension systems? A. B. C.
4.
What are the two most commonly used shock absorbers? A. B.
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5. Match the descriptions to the suspension terms. All the descriptions will not be used. ____ A. Aeration ____ B. Ball joint ____ C. Coil spring ____ D. Control arm ____ E. Kingpin ____ F. Leaf spring ____ G. Shock absorber ____ H. Stabilizer bar ____ I. Strut rod 6. 7. 8. 9. 10. 11. 5. 1. 2. 3. 4. Also called A arms or wishbones. Minimizes swaying and leaning of vehicle during turns. Steel bar wound into a coil. Connects the control arm to the steering knuckle; has the ability to tilt and rotate. A coil spring and shock absorber combination. Causes fluid to foam. Constructed of one or more leaves. Supports the wheel bearings and may be integrated with the knuckle. Stabilizes the lower control arm. Allows steering knuckle to pivot on axle. Dampens spring movement.
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AS1-L3-UVII REAR SUSPENSION TYPES AND COMPONENTS
Directions Answer the following questions by writing all responses on this sheet. 1. In the leaf spring rear suspension, which component allows the leaf spring to change length as the vehicle travels over a rough surface?
NAME:
DATE:
2.
In what position is a transverse spring mounted in a vehicle?
3.
On rear-wheel-drive coil spring suspensions, which component is used to control axle movement?
4.
What component controls lateral axle movement in most trailing arm rear suspensions?
5.
In which type of suspension is a unit, composed of a coil spring and shock absorber, mounted at each rear wheel?
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JS1-L1-UVIII DIAGNOSE A SHORT- AND LONG-ARM (SLA) SUSPENSION SYSTEM
Equipment: Personal protective equipment (PPE) Tape measure Dial indicator or ball joint gauge Hand tools Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
DATE: NAME(S):
EVALUATION
3.
Road test the vehicle to note suspension system concerns. Use the checklist below to record results. CAUTION: Always obtain the instructor's approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time. a. b. c. d. e. Suspension system noises Vehicle body sway Vehicle bounce Vehicle roll on turns OK_____ OK_____ OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
Describe any other suspension concerns below.
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Determine the necessary action for any concern noted in the road test and record below.
4.
Perform a visual inspection of SLA suspension components. Use the checklist below to record results. a. b. c. d. e. f. Inspect control arms for damage. Inspect control arm bushings for wear. Inspect springs for damage. Inspect sway bar, links, and bushing. Inspect shock absorbers for leakage. Inspect shock absorber bushing. OK_____ OK_____ OK_____ OK_____ OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
Determine the necessary action for any item marked Not OK and record below.
5. 6.
Jounce the vehicle and note any noise produced by the suspension system. Using service information, locate a procedure for measuring the vehicle's ride height. Make sure the procedure also provides the points on the vehicle to take ride height measurements. Also make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, measure the vehicle's ride height at all four corners of the vehicle. Perform the following tasks before taking the measurements.
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a. b. c. d. e. Make sure the vehicle is on a level surface when taking measurements. Inflate tires to the recommended pressure. Make sure the tires are the proper size and type. Fill the fuel tank completely when taking ride height measurements. If the tank is not full, add equivalent weight to the vehicle. Remove all unnecessary weight from the vehicle, such as luggage or other nonessential cargo. Do not allow anyone to sit in or lean on the vehicle while taking measurements. Clean all foreign material from the areas at which the measurements are to be taken. Jounce the vehicle vigorously and allow the suspension to settle.
f. g. 7.
Record the ride height measurements below. If the height is not correct, suggest procedures for solving the problem.
8.
9.
Inspect the general condition of the ball joints. Use the chart below to indicate the condition of various ball joint parts. Grease seal Grease fitting Stud nut/Cotter pin OK OK OK NOT OK NOT OK NOT OK
Determine the necessary action for any item marked "NOT OK" above and record below.
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10. Using service information, locate a procedure for lifting the vehicle to unload the load-carrying ball joints. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Use this procedure only if necessary in step 11. 11. Lower the vehicle. Using service information, locate a procedure for evaluating the condition of the load-carrying ball joints. Ensure that the procedure includes tests for radial looseness and axial play. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, E.)
Using the procedure, evaluate the load-carrying ball joints. If necessary, unload the ball joints, using the procedure listed in step 10 of this job sheet. Record observations.
12.
Using service information, locate a procedure for evaluating the condition of the nonload-carrying ball joints. Ensure that the procedure includes tests for looseness. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, G.)
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Using the procedure, evaluate the nonload-carrying ball joints. observations. Record
13.
Record the specifications related to the ball joint movement. Compare this to the above tests. Based on the comparison, record the condition of the ball joints.
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JS2-L1-UVIII LUBRICATE A STEERING AND SUSPENSION SYSTEM
Equipment: Grease gun Hand tools Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
DATE: NAME(S):
EVALUATION
3.
4.
Record the type of lubricant recommended for the vehicle's steering and suspension. Recommended lubricant ________________________
5.
Inspect all steering and suspension joint grease seals. If any seals are torn or missing, replace them. Record observations.
NOTE: If the seal is an integral part of the joint, replace the entire joint. CAUTION: Use a hand-operated, low-pressure grease gun. A high-pressure, air-operated gun can easily rupture seals, especially if a novice is using it.
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6. 7. Wipe all grease from each grease fitting. If plugs are used instead of fittings, install temporary fittings. Apply grease to each fitting until grease begins to flow out of the bleed area at the base of the seal or until the seal starts to swell. CAUTION: Do not continue to force lubricant into a socket after the seal starts to swell; doing so ruptures the seal. Make sure to use the proper grease. Most suspension and steering systems use an extreme pressure (EP) grease. 8. 9. Apply a heavy film of grease to the steering stops on the steering knuckle and control arms. Wipe excessive grease from all joints, reinstall plugs, and lower the vehicle.
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JS1-L2-UVIII INSPECT AND REPLACE CONVENTIONAL OR GAS-CHARGED SHOCK ABSORBERS
Equipment: Hand tools Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. CAUTION: It is important to support the axle during shock removal to prevent the axle from dropping down and causing injury or damaging the brake line.
4.
Carefully inspect the shock absorbers. Record the inspection results below. Secureness of Mounting Condition of Rubber Bushings Amount of Fluid Leakage Condition of Piston Rod and Tube OK OK OK OK Not OK Not OK Not OK Not OK
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If any of the above items are marked "Not OK," determine necessary action and record below.
5.
Using the procedure outlined below, remove the shock absorber. a. b. Hold the piston rod to keep it from turning. Remove the upper shock absorber retaining nut, washer, and rubber bushing. Remove the bolts that hold the lower end of the shock absorber to the lower control arm and then remove the shock absorber.
6.
Extend and compress the piston rod through several full strokes and then complete the chart below. Smooth Action Noise Resistance to Movement in Both Directions OK OK OK Not OK Not OK Not OK
Shock Expands When Released From Compressed Position (Gas Charged Only) OK
Not OK
If any of the items above are marked "Not OK," determine the necessary action and record below.
7.
Hold the shock in an upright position and fully extend it. Next, turn the shock over and fully compress it. Repeat this action three times to expel any air trapped in the hydraulic cylinder. Once again extend and compress the piston rod through several full strokes and complete the following chart. Smooth Action Noise OK OK Not OK Not OK
8.
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Resistance to Movement in Both Directions Expansion of Gas-Charged Shock When Released From Compressed Position OK Not OK
OK
Not OK
If any of the items are marked "Not OK," determine the necessary action and record below.
9.
Using the procedure outlined below, install the shock absorber. a. Using service information, determine all torque specifications related to the installation of the shock absorber. Record the specifications in the space below.
b. c. d. e. f. g.
Using the procedure described in step 7 of this job sheet, bleed any air trapped in the shock absorber. Fully extend the shock absorber and install the lower mounting washer and grommet on the piston rod. Insert the shock through the opening in the control arm and allow the piston rod stem to pass through the upper mounting hole. Install the upper mounting grommet and washer and then install and tighten the retaining nut and bolt to the specified torque. Install and tighten the bolts and nuts that retain the lower end of the shock to the specified torque. Lower the vehicle.
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JS2-L2-UVIII INSPECT AND REPLACE AIR-ADJUSTABLE SHOCK ABSORBERS
Equipment: Hand tools Vehicle lifting equipment Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. CAUTION: It is important to support the axle during shock removal to prevent the axle from dropping down and causing injury or damaging the brake line.
4.
Visually inspect the shock absorbers. Record the inspection results below. Secureness of Mounting Condition of Rubber Bushings Amount of Fluid Leakage Condition of Piston Rod and Tube Air lines Air line fittings OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK
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If any of the items are marked "Not OK," determine necessary action and record below.
5.
Inflate the shocks to the maximum pressure recommended by the manufacturer and inspect the condition of the rubber air boots. Record observations below, including the description of any repairs made.
6.
Using the procedure outlined below, remove the shock absorber. a. b. c. d. Discharge all air from the system. Disconnect the air line from the shock absorber. Remove the upper shock mounting. Remove the lower shock mounting and the shock absorber.
7.
Inspect the condition of the plastic air lines and connectors. Repair or replace any damaged or broken lines. Describe below any repairs made to the air lines.
8.
Using the procedure outlined below, install the air adjustable shock absorber. a. Determine all torque specifications related to the installation of the shock absorber. Record the specifications below.
b. c.
Install washers and rubber grommets on the shock, as needed. Attach the lower shock mounting and tighten it to the specified torque.
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d. e. 9. Attach the upper shock mounting and tighten it to the specified torque. Connect the air lines.
Inflate the shock absorbers to the maximum specified pressure. a. b. c. Prepare a soapy water solution and apply it to all connections. Inspect for leaks at all connections and make repairs, as necessary. Lower the vehicle.
10.
Adjust shocks to the desired height/pressure.
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JS3-L2-UVIII INSPECT AND REPLACE STABILIZER BARS AND BUSHINGS
EVALUATION NAME(S):
DATE:
3.
Jounce the vehicle and note any noise that the stabilizer assembly produces. Record observations.
4.
5.
Visually inspect the condition of the stabilizer bar, bushings, and links. Record the inspection results below. Stabilizer Bar Stabilizer Bar Bushings Mounting Brackets and Links OK OK OK Not OK Not OK Not OK
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If any of the items are marked "Not OK," determine the necessary actions and record below.
6.
Grasp the bar and shake it. Note any movement in the bushings. Record observations below.
7.
Using the procedure outlined below, remove the stabilizer bar. a. b. Remove the link bolts or brackets that connect the stabilizer to the control arms. Remove the brackets that connect the stabilizer to the frame and remove the stabilizer and bushings.
8.
Inspect the condition of the bushings, brackets, and links. Record observations.
9.
Using the procedure outlined below, install the stabilizer. a. Determine all torque specifications related to the installation of the stabilizer. Record the specifications in the space below.
b. c. d.
Reverse the removal procedures to install the stabilizer. Replace all damaged or missing parts as directed by the instructor. Lower the vehicle.
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JS4-L2-UVIII INSPECT AND REPLACE STRUT RODS AND BUSHINGS
EVALUATION NAME(S):
DATE:
3.
4.
Inspect the condition of the strut rods and bushings. Record the inspection results. Strut Rods Strut Bushings OK OK Not OK Not OK
If any of the above items are marked "Not OK," determine the necessary actions and record below.
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5. Using service information, locate a procedure for removing the strut rods and bushings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, B.)
Using the procedure, remove the strut rods and bushings. Record observations.
6.
Inspect the strut rods and bushings. Record observations.
7.
Using service information, locate a procedure for installing the strut rods and bushings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, D.)
Using the procedure, install the strut rods and bushings. Record observations.
8.
Lower the vehicle. Check and reset all wheel alignment angles as necessary. See the instructor for wheel alignment procedures.
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JS1-L3-UVIII INSPECT AND REPLACE COIL SPRINGS
Equipment: Hand tools Vehicle lifting equipment Specialty tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Inspect the coil spring. Note any broken or collapsed coils. Also note any evidence of coil clash. Record observations below.
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5. Using service information, locate a procedure for removing the coil spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, Aspring mounted on lower control arm or Section III, Aspring mounted on upper control arm.)
Using the procedure, remove the coil spring. Record observations below. CAUTION: Follow the manufacturer's instructions carefully during removal and installation; failure to do so could result in serious personal injury.
6.
Inspect the condition of the coil spring and related components. Complete the chart below. a. b. c. d. e. f. Coil springs Control arms Stud and the tapered hole in the steering knuckle Disconnected control arm bushings and bolts Shock absorber Disconnected stabilizer and strut rod bushings OK OK OK OK OK OK NOT OK NOT OK NOT OK NOT OK NOT OK NOT OK
If any of the above items were marked "NOT OK," describe the problem and suggest the appropriate actions below.
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7. Using service information, locate a procedure for installing the coil spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, Cspring mounted on lower control arm or Section III, Bspring mounted on upper control arm.)
Using the procedure, install the coil spring. a. b. c. 8. Clean the spring mounting pads before installation. Be sure to reinstall any rubber insulators before installing the spring. Tighten all fasteners to the specified torque.
Lower the vehicle. Move the vehicle at least 30 ft and park it on a flat, level surface. Jounce the vehicle several times. Allow it to settle out and check chassis height. Check and reset all alignment angles as necessary. See the instructor for wheel alignment procedures.
9.
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JS2-L3-UVIII INSPECT AND REPLACE TORSION BAR SPRINGS
Equipment: Vehicle lifting equipment Hand tools Specialty tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. Make sure the wheels are in the full rebound position. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Using service information, locate a procedure for removing the torsion bar spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, A.)
Using the procedure, remove the torsion bar spring. Record observations below.
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CAUTION: Follow the manufacturer's instructions carefully during removal and installation; failure to do so could result in serious personal injury. 5. Inspect the condition of the torsion bar spring and related components. Fill out the chart below. Seal, if used Torsion bar (Look for nicks or scoring.) Adjusting bolt assembly, mounts, and bushings OK OK OK NOT OK NOT OK NOT OK
6.
Using service information, locate a procedure for installing the torsion bar spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section IV, C.)
Using the procedure, install the torsion bar spring. a. b. c. Clean spring mounting points before installation. Replace all damaged or missing parts as directed by the instructor. Tighten all fasteners to the specified torque.
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7. Using service information, locate a procedure for adjusting the torsion bar ride height. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, adjust the torsion bar ride height. Record observations below.
8.
Check and reset all alignment angles as necessary. See the instructor for wheel alignment procedures.
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JS3-L3-UVIII INSPECT AND REPLACE BALL JOINTS
Equipment: Hand tools Vehicle lifting equipment Taper-breaking tool for ball joints Specialty tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. Place safety stands under the lower control arm. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. CAUTION: The spring and control arm must be retained throughout the removal and installation of the ball joint. Therefore, safety stands must remain under the lower control arm at all times during these procedures.
4.
Check the condition of the ball joints. Refer to JS1-L1-UVIII for this procedure. Record observations below.
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5. Using service information, locate a procedure for removing the ball joint. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, Cload-carrying ball joint or Section V, Dnonload-carrying ball joint.)
Using the procedure, remove the ball joint. Record observations below.
6.
Thoroughly clean and carefully inspect the tapered hole in the steering knuckle. Clean the ball joint mounting area of the control arm. Inspect for cracking or distortion. Record observations below.
7.
Using service information, locate a procedure for installing the ball joint. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, Cload-carrying ball joint or Section V, Dnonload-carrying ball joint.)
Using the procedure, install and lubricate the ball joint. Refer to JS2-L1-UVIII for the lubrication procedure. Record observations below.
8.
Lower the vehicle. Check and reset all alignment angles as necessary. See the instructor for wheel alignment procedures.
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JS4-L3-UVIII INSPECT AND REPLACE LOWER CONTROL ARMS AND BUSHINGS
Equipment: Hand tools Vehicle lifting equipment Taper-breaking tool for ball joints Specialty tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Inspect the condition of the control arm and bushings. Complete the chart below. Control arm bushings OK Control arm Noise when jounced OK OK NOT OK NOT OK NOT OK
4.
Use proper lifting equipment to raise the vehicle. (If the spring is on the upper control arm, place a wood block between the upper arm and the side rail before raising the vehicle.)
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CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. 5. Using service information, locate a procedure for removing the lower control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, B.)
Using the procedure, remove the lower control arm. Also inspect the condition of the ball joint seal and tapered stud. Check the tapered hole in the steering knuckle for wear. Record observations below. NOTE: Mark the position of the alignment cams on vehicles that have the spring on the upper control arm. CAUTION: Follow the manufacturer's instructions carefully during removal and installation; failure to do so could result in serious personal injury.
6.
Using service information, locate a procedure for replacing the lower control arm bushings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, C.)
Using the procedure, replace the lower control arm bushings. Record observations below.
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CAUTION: To prevent crushing the control arm, be sure to support the inner portion of the control arm when pressing bushings. 7. Using service information, locate a procedure for reinstalling the control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, reinstall the control arm. a. b. Clean all mounting points on the control arm and frame before beginning installation procedures. Reinstall the control arm. When installing the arm on vehicles that have the spring on the upper arm, align the marks made before removal. Tighten all fasteners to the specified torque.
c. 8.
Lower the vehicle. Check and reset all alignment angles as necessary. See the instructor for wheel alignment procedures.
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JS5-L3-UVIII INSPECT AND REPLACE UPPER CONTROL ARMS AND BUSHINGS
Equipment: Hand tools Vehicle lifting equipment Taper-breaking tool for ball joints Control arm bushing press Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Inspect the condition of the control arm and bushings. Fill out the chart below. Control arm bushings (rubber) Control arm bushings (metal) Cross-shaft nuts Control arm OK OK OK OK NOT OK NOT OK NOT OK NOT OK
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4. Use proper lifting equipment to raise the vehicle. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions. CAUTION: The positioning of the safety stands depends on the location of the spring. If the spring rests on the upper control arm, place the safety stands under the frame. If the spring rests on the lower control arm, place the safety stands between the spring seat and the ball joint. 5. Using service information, locate a procedure for removing the vehicle's upper control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VII, B.)
Using the procedure, remove the vehicle's upper control arm. Record observations below. CAUTION: Follow the manufacturer's instructions carefully during removal and installation; failure to do so could result in serious personal injury.
6.
Using service information, locate a procedure for removing and replacing the control arm shaft and bushings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VII, Crubber bushings or Section VII, Dmetal bushings.)
Using the procedure, replace the control arm shaft and bushings. Record observations below.
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7. Using service information, locate a procedure for reinstalling the control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, reinstall the control arm. a. b. c. d. e. f. 8. Clean all mounting points on the control arm and frame before beginning installation procedures. Reinstall the control arm either by aligning the marks made before removal or by installing the alignment shims in the same positions. Tighten all fasteners to the specified torque. On control arms using rubber bushings, do not tighten cross-shaft nuts until the vehicle is at rest on the floor. Lower the vehicle. If necessary, tighten cross-shaft nuts.
Check and reset all alignment angles as necessary. See the instructor for wheel alignment procedures.
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JS1-L4-UVIII DIAGNOSE STRUT SUSPENSION SYSTEMS
Equipment: Personal protective equipment (PPE) Tape measure Dial indicator or ball joint gauge Hand tools Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Road test the vehicle to note suspension system concerns. Use the checklist below to record results. CAUTION: Always obtain the instructor's approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time. a. b. c. d. e. Suspension system noises Vehicle body sway Vehicle bounce Vehicle roll on turns OK_____ OK_____ OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
Describe any other suspension concerns below.
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Determine the necessary action for any concern noted in the road test and record below.
4.
Perform a visual inspection of strut suspension components. Use the checklist below to record results. a. b. c. d. e. f. g. h. Inspect control arms for damage. Inspect control arm bushings for wear. Inspect springs for damage. Inspect sway bar, links, and bushing. Inspect struts for leakage. Inspect strut mounts and bearings for damage. Inspect strut dampers for damage. Inspect jounce bumpers for wear. OK_____ OK_____ OK_____ OK_____ OK_____ OK_____ OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
Determine the necessary action for any item marked Not OK and record below.
5. 6.
Jounce the vehicle and note any noise produced by the suspension system. Using service information, locate a procedure for measuring the vehicle's ride height. Make sure the procedure also provides the points on the vehicle to take ride height measurements. Also make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
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Using the procedure, measure the vehicle's ride height at all four corners of the vehicle. Perform the following tasks before taking the measurements. a. b. c. d. Make sure the vehicle is on a level surface when taking measurements. Inflate tires to the recommended pressure. Make sure the tires are the proper size and type. Fill the fuel tank completely when taking ride height measurements. If the tank is not full, add equivalent weight to the vehicle. Remove all unnecessary weight from the vehicle, such as luggage or other nonessential cargo. Do not allow anyone to sit in or lean on the vehicle while taking measurements. Clean all foreign material from the areas at which the measurements are to be taken. Jounce the vehicle vigorously and allow the suspension to settle.
e.
f. g. 7.
Record the ride height measurements below. If the height is not correct, suggest procedures for solving the problem.
8.
9.
Inspect the general condition of the ball joints. Use the chart below to indicate the condition of various ball joint parts. Grease seal Grease fitting Stud nut/Cotter pin OK OK OK NOT OK NOT OK NOT OK
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Determine the necessary action for any item marked "NOT OK" and record below.
10.
Using service information, locate a procedure for evaluating the condition of the ball joints. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, evaluate the ball joints and compare the results to specifications. Based on the comparison, record the condition of the ball joints below.
11.
Using service information, locate a procedure for evaluating the condition of the strut mounts and bearings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, evaluate the strut mounts and bearings. Record observations below.
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JS2-L4-UVIII REMOVE, INSPECT, AND INSTALL STRUT ASSEMBLIES
DATE: NAME(S):
EVALUATION
3.
Use proper lifting equipment to raise the vehicle from under the frame, allowing the suspension to hang free. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Inspect the strut condition. Record the inspection results below. Damper Spring Strut Mount Strut Jounce Bumper OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK
If any of the above items are marked "Not OK," determine the necessary actions and record below.
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5. Using service information, locate a procedure for removing the strut assembly. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, A.)
Using the procedure, remove the strut assembly. 6. Using service information, locate a procedure for installing the strut assembly. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, F.)
Using the procedure, install the strut assembly. 7. Lower the vehicle.
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JS3-L4-UVIII REPLACE STRUT DAMPERS, SPRINGS, AND MOUNTS
Equipment: Coil spring compressor for strut Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the specifications in the space below.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. Allow the front suspension to hang free. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Remove the strut assembly from the vehicle, if required. NOTE: For this procedure, refer to JS2-L4-UVIII.
5.
Using service information, locate a procedure for disassembling the strut assembly. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, B.)
Using the procedure, disassemble the strut assembly.
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CAUTION: Use only coil spring compressors that are approved for strut service. Make certain that the coil spring compressor is securely installed on the compressed spring before removing the upper piston rod nut. 6. Inspect the condition of the strut components and record the results below. Strut Mount (Rubber Mount and Bearing) Strut housing Spring Damper Leakage Jounce Bumper OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK
If any of the above items are marked "Not OK," describe the problem and determine the necessary actions in the space below.
7.
Bench test the damper and record the results below.
8.
Using service information, locate a procedure for replacing the damper cartridge. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, C.)
If the strut is equipped with a replaceable damper cartridge, remove the strut damper and install a cartridge. If working with a sealed strut, skip this procedure and go to step 10.
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9. Using service information, locate a procedure for reassembling the strut assembly. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, E.)
Using the procedure, reassemble the strut assembly. a. b. 10. Replace all worn or missing parts as directed by the instructor. Be certain the spring is properly aligned and seated in the spring mounts as shown in the service information.
Install the strut assembly on the vehicle if required. For this procedure, refer to JS2-L4-UVIII.
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JS1-L1-UIX INSPECT AND REPLACE REAR LEAF SPRINGS
Equipment: Hand tools Personal protective equipment (PPE) Special tools as needed Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Visually inspect the condition of the leaf spring. Record the results of the inspection below. Spring leaves Tie bolt Inner leaves U-bolts Rebound clips Shackles and bushings OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK______ OK_____ Not OK______
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If any of the items are marked "Not OK," describe the problem and determine the necessary actions. Record below.
5.
Using service information, locate a procedure for removing the leaf spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, B.)
Using the procedure, remove the leaf spring. Record observations below.
CAUTION: Leaf springs are very heavy. Ask an assistant to hold and lower the spring assembly from the vehicle. Serious personal injury can result from being struck by a falling spring. 6. Inspect the components listed in step 4. In the space below, record any problems found in the spring components and determine necessary actions.
7.
Using service information, locate a procedure for replacing the spring eye bushing. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
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Using the procedure, replace the spring eye bushing. Record observations below.
8.
Using service information, locate a procedure for installing a leaf spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, E.)
Using the procedure, install the leaf spring. Record observations below.
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JS2-L1-UIX REMOVE, INSPECT, AND INSTALL TRANSVERSE SPRING SYSTEMS
DATE: NAME(S):
Equipment: Hand tools Vehicle lifting equipment Special tools as needed Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
4.
Visually inspect the transverse spring and related components. Record the results on the checklist below. Transverse spring Spring links Control arms Bushings Mounts OK_____ NOT OK_____ OK_____ NOT OK_____ OK_____ NOT OK_____ OK_____ NOT OK______ OK_____ NOT OK______
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5. Using service information, locate a procedure for removing a transverse spring and related components. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, remove the transverse spring. Record observations below.
CAUTION: Springs produce great pressure and service procedures must be followed closely to prevent injury. 6. Inspect the components listed in step 4. In the space below, record any problems found with the spring or related components and suggest the appropriate actions.
7.
Using service information, locate a procedure for installing a transverse spring and related components. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the transverse spring. Record observations below.
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JS3-L1-UIX INSPECT AND REPLACE REAR COIL SPRINGS AND INSULATORS
DATE: NAME(S):
EVALUATION
3.
4.
Visually inspect the coil spring. Record any problems found during the inspection (e.g., broken or collapsed coils or evidence of coil spring clash).
5.
Using service information, locate a procedure for removing the rear coil spring from the vehicle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, C.)
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Using the procedure, remove the rear coil spring. Record observations below.
CAUTION: Be sure to follow the manufacturer's instructions carefully during removal and installation of the rear coil spring. Failure to do so can result in serious personal injury. 6. Inspect the rear coil spring components. Use the checklist below to note any damage. Control Arms OK_____ Not OK_____
Disconnected Control Arm Bushings and Bolts, if Applicable OK_____ Not OK_____ Shock Absorber Disconnected Stabilizer Bushings OK_____ Not OK_____ OK_____ Not OK_____
If any of the above items are marked "Not OK," describe the problem and determine necessary actions.
7.
Using service information, locate a procedure for installing the coil spring. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section II, E.)
Using the procedure, install the coil spring. 8. Lower the vehicle.
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JS4-L1-UIX INSPECT AND REPLACE REAR SUSPENSION CONTROL ARMS AND BUSHINGS
Equipment: Hand tools Personal protective equipment (PPE) Special tools Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
4.
Visually inspect the control arms and track rod. Use the checklist below to note any damage. Upper and lower control arms Control arm bushings Track rod Track rod bushings Track rod mounting brackets OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK_____ OK_____ Not OK_____
If any of the above items are marked "Not OK," describe the problem and determine necessary actions.
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5. Using service information, locate a procedure for removing the control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, Blower arm and Cupper arm.)
Using the procedure, remove the rear suspension control arm. Record observations.
6.
Inspect the control arm and related components. In the space below, record any problems found with the spring or related components and suggest the appropriate actions.
7.
Using service information, locate a procedure for removing and replacing the control arm bushings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, D.)
Using the procedure, replace the control arm bushings. Record observations.
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8. Using service information, locate a procedure for installing the control arm. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the control arm. Lower the vehicle when installation is complete. Record observations.
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JS5-L1-UIX INSPECT AND REPLACE REAR SUSPENSION SHOCK ABSORBERS
DATE: NAME(S):
EVALUATION
3.
Use proper lifting equipment to raise the vehicle. CAUTION: It is important to support the axle during shock removal to prevent the axle from dropping down and causing injury or damaging the brake line. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Carefully inspect the shock absorbers for the following: Secureness of mounting Condition of rubber bushings Amount of fluid leakage Condition of piston rod and tube OK OK OK OK Not OK Not OK Not OK Not OK
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If any of the above items are marked "Not OK," describe the problem and determine the necessary actions.
5.
Using the procedure outlined below, remove the shock absorber. NOTE: Do not grasp the piston rod with a wrench or pliers. Use the flats provided at the end of the piston rod. a. b. Secure the piston rod to keep it from turning. Remove the upper shock absorber retaining nut, washer, and rubber bushing. Remove the bolts or nut holding the lower end of the shock absorber to the axle and remove the shock absorber.
6.
Inspect the shock absorber by fully extending and compressing the piston rod several times. Complete the following checklist. NOTE: Extreme force is required to compress a gas-charged shock; therefore, this inspection procedure may be difficult to perform on a gascharged shock. Is the action rough? Does the shock make any unusual noise? Does the shock exhibit resistance to movement in both directions? Does the shock expand when released from a compressed position (gas charged only) Yes Yes No No
Yes
No
Yes
No
If any of the above items are marked "Yes," describe the problem and determine necessary action. Record below.
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7. Hold the shock in an upright position and extend it fully. Then turn it over and compress it fully. Repeat this action three times to expel any air trapped in the hydraulic cylinder. Repeat step 6 and record the results below.
8.
9.
Using the procedure outlined below, install the shock absorber. a. Using appropriate service information, determine any torque specifications related to installing the shock absorber. Record the specifications.
b.
Hold the removed shock in an upright position and extend it fully. Then turn it over and compress it fully. Repeat this action at least three times to expel any air trapped in the hydraulic cylinder. Fully extend the shock absorber and install the lower mounting washer and grommet, if used, on the piston rod. Insert the shock through the upper mounting hole. Install the upper mounting grommet and washer. Then install and tighten the retaining nut to the specified torque. Install and tighten the bolts or nut retaining the lower end of the shock to the specified torque.
c. d. e. f. 10.
Lower the vehicle.
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AS1-L1-UX ELECTRONIC SUSPENSION CONTROL SYSTEMS
Directions Answer the following questions by writing all responses on this sheet. 1. What is the basic difference between conventional suspension systems and electronic suspension control systems?
NAME:
DATE:
2.
Which electronic suspension control system is the simplest and what is its function?
3.
How do the actuators in a variable-ratio shock or strut system operate to control the ride?
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4. What is the purpose of an air spring system and which component fills the air springs with air?
5.
What are the two types of electronic handling control systems and what are their functions? A.
B.
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JS1-L2-UX TEST ELECTRONIC LEVEL CONTROL PERFORMANCE
Equipment: Hand tools Ammeter 0-psi (pounds per square inch) to 150-psi pressure gauge Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3. 4. 5. 6.
Disconnect the wiring harness at the compressor motor and the exhaust solenoid terminals. Disconnect the pressure line from the dryer and attach a 0-psi to 150-psi pressure gauge to the dryer fitting. Connect a 12-volt power supply to the compressor with an ammeter connected in series between the power supply and the compressor. While monitoring the ammeter reading, run the compressor. When pressure reaches 110 psi, shut off the compressor and observe the pressure gauge. Use the following checklist to record the findings. Does the current draw exceed 14 amp? Does the compressor fail to reach 110 psi? Does pressure leak off? YES_____ NO_____ YES_____ NO_____ YES_____ NO_____
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If any of the previous items were marked "YES," refer to the appropriate service information for guidance. Describe the problem and suggest the appropriate actions below. If all the above items were marked "NO," proceed to step 7.
7.
Reconnect the wiring and air line.
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JS2-L2-UX LEAK TEST AN ELECTRONIC LEVEL CONTROL SYSTEM
DATE: NAME(S):
Equipment: Hand tools 0-psi (pounds per square inch) to 150-psi pressure gauge Shut-off valve Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3. 4.
Tee the pressure gauge into the system between the dryer and the air line. Make sure the shut-off valve is on the compressor side of the gauge. Open the shut-off valve and apply shop air through the Schrader valve until the gauge reads 100 psi to 120 psi. Note the pressure gauge. Does the pressure hold steady? YES_____ NO_____ If the answer is "YES," go to step 8 of this job sheet. If the answer is "NO," go to step 5 of this job sheet.
5.
Isolate the compressor by closing the shut-off valve. Does the pressure hold steady? YES_____ NO_____ If "YES" was marked, go to step 6 of this job sheet. If "NO" was marked, go to step 7 of this job sheet.
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6. Apply a soapy water solution to all components except the compressor and observe for leaks. Record observations below.
7.
Apply a soapy water solution to the compressor assembly and observe for leaks. Record observations below.
8.
Based on the results of the tests and inspections performed in this job sheet, describe the condition of the system and recommend the appropriate actions below.
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JS3-L2-UX REMOVE AND INSTALL AN ELECTRONIC LEVEL CONTROL COMPRESSOR
Equipment: Hand tools Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for removing and reinstalling the compressor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, E.)
Using the procedure, remove the compressor. Record observations below.
4.
Inspect the condition of the air line and wiring after they are disconnected from the vehicle. Record observations below.
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5. Using the procedure from step 3 of this job sheet, install the compressor. Record observations below.
6.
Test the performance of the compressor. For this procedure, refer to JS1-L2-UX. Record the results of the performance test below.
7.
Leak test the air line connection at the compressor with a soapy water solution. Record results below. NO LEAKS_____ LEAKS FOUND_____ If leaks are found, they must be repaired.
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JS4-L2-UX TEST AN ELECTRONIC LEVEL CONTROL HEIGHT SENSOR
Equipment: Hand tools Vehicle lifting equipment Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
Use proper lifting equipment to raise the vehicle. Support the axle so it is as close as possible to normal ride height. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
4.
Using service information, locate a procedure for testing the operation of the height sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section I, A.)
Using the procedure, test the height sensor. Use the checklist below to record the test results. Lower the vehicle when the test is completed. Do the shock absorbers fill when the control arm is moved upward? Does the compressor stop running when the control arm is moved down? YES_____ NO______ YES_____ NO_____
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Do the shock absorbers deflate when the control arm is moved downward? Is there a proper amount of delay before the shock absorber responds? YES_____ NO______ YES_____ NO_____
If any of the previous items were marked "NO," describe the problem and recommend the appropriate actions below.
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JS5-L2-UX TEST AND DIAGNOSE COMPONENTS OF ELECTRONICALLY CONTROLLED SUSPENSION SYSTEMS USING A SCAN TOOL
Equipment: Scan tool Personal protective equipment (PPE) Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Using service information, locate a procedure for connecting a scan tool and retrieving diagnostic trouble codes from an electronically controlled suspension system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, retrieve the codes. Record observations below.
4.
Use service information to interpret the diagnostic trouble codes.
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5. Using service information, locate a diagnostic chart to determine steps needed to pinpoint problems in the electronic suspension system. Describe the problem in the space below.
6.
Perform the necessary procedures to correct the problem. Describe the procedures in the space below.
7.
After repairs have been performed, use the scan tool to test the system to be sure no problems exist.
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AS1-L1-UXI WHEEL BEARINGS
Directions Answer the following questions by writing all responses on this sheet. 1. What type of wheel bearing is most commonly used on rear-wheel-drive vehicles and why is it used?
NAME:
DATE:
2.
What are the four major parts of a tapered roller wheel bearing? A. B. C. D.
3.
The outer wheel bearing cones are pressed into what component?
4.
The wheel bearings are supported by what component?
5.
What kind of tapered roller or ball bearings do many of today's frontwheel-drive vehicles use?
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JS1-L2-UXI SERVICE NONSEALED TAPERED ROLLER WHEEL BEARINGS
Equipment: Bearing cone drivers Dial indicator Hand tools Personal protective equipment (PPE) Seal driver Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Using service information, locate a procedure for removing the wheel bearings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section III, B.)
Using the procedure, remove the wheel bearings. Record observations below.
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5. Clean the hub and wheel bearings. a. Using a clean shop towel, wipe the grease out of the hub. Avoid getting grease on the friction surfaces of the rotor. NOTE: If the rotor is in two pieces, work on the hubs with the friction disk removed. CAUTION: Keep all wheel bearings in sets and return them to the spindle from which they were taken. Do not replace defective wheel bearings with used wheel bearings. b. Use a solvent to thoroughly wash the wheel bearings (and all of the other parts removed with them). Using compressed air, blow out all old grease from the bearing. Make sure to remove all grease from the inside of the bearing. Rewash the bearings and accompanying parts.
CAUTION: Do not allow the bearing to spin on the finger(s) while blow-drying the bearing; doing so may result in personal injury. 6. Inspect the spindle, bearings, and hub. Use the checklist below to note any problems. Spindle condition Bearing cones Bearing cages Bearing rollers Hub condition OK_____ OK_____ OK_____ OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
If any of the above items are marked "Not OK," describe the problem and determine necessary action for correcting it.
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7. Using service information, locate a procedure for repacking, installing, and adjusting the wheel bearings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Sections III, B and IV, A.)
Using the procedure, repack, install, and adjust the wheel bearings. Record observations below.
8. 9.
Reassemble the remaining brake and wheel assembly components. Lower the vehicle.
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JS2-L2-UXI REMOVE AND INSTALL SEALED FRONT-WHEEL BEARINGS: FRONT-WHEEL-DRIVE VEHICLES
NAME(S):
DATE:
EVALUATION
3.
4.
Using service information, locate a procedure for removing the frontwheel bearing. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, remove the front-wheel bearing. Record observations below.
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5. Clean and inspect the steering knuckle and constant velocity joint splines and nut. In the space below, record any defects found and suggest procedures to correct them.
6.
Using service information, locate a procedure for installing the frontwheel bearing. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the front-wheel bearing. Tighten all fasteners to the specified torque and lower the vehicle when installation is complete. Record observations below.
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JS3-L2-UXI REMOVE AND INSTALL SEALED REAR-WHEEL BEARINGS: FRONT-WHEEL-DRIVE VEHICLES
Equipment: Hand tools Personal protective equipment (PPE) Special tools as needed Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
4.
Using service information, locate a procedure for removing the rearwheel bearings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, remove the wheel bearing. Record observations below.
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5. Clean and inspect the backing plate and mounting bolts. In the space below, record any defects found and determine the necessary action to correct them.
6.
Using service information, locate a procedure for installing the rear-wheel bearings. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, install the rear-wheel bearings. Tighten all fasteners to the specified torque and lower the vehicle when installation is complete. Record observations below.
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JS4-L2-UXI REMOVE, INSPECT, AND INSTALL A WHEEL SPINDLE /KNUCKLE
Equipment: Ball joint taper-breaking tool Hand tools Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing the procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Using service information, locate a procedure for removing a wheel spindle/knuckle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, B.)
Using the procedure, remove the wheel spindle/knuckle. Record observations below.
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5. Inspect the spindle/knuckle assembly. Use the checklist below to note any problems. Grease seal surface Spindle threads Surface on which inner cones rest Fit of inner cones OK_____ OK_____ Not OK_____ Not OK_____ Not OK_____ Not OK_____
OK_____ OK_____
If any of the above items are marked "Not OK," describe the problem and determine necessary action for correcting it. Record below.
6.
Using service information, locate a procedure for installing a wheel spindle/knuckle. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI, C.)
Using the procedure, install the wheel spindle/knuckle. Tighten all fasteners to the specified torque. Lower the vehicle when reinstallation is completed. Record observations below.
NOTE: Be sure to inspect and repack the wheel bearings before installing the spindle/knuckle. Refer to JS1-L2-UXI for this procedure. Average of the above evaluations
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AS1-L1-UXII WHEEL BASICS
Directions Answer the following questions by writing all responses on this sheet. 1. Name the five basic parts of a wheel. A. B. C. D. E. 2. How is wheel size designated?
NAME:
DATE:
3.
What is the purpose of safety rims on a wheel?
4.
Answer the following questions about wheel offset. A. What is wheel offset?
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B. What problems can be caused by putting a wheel with the wrong offset on a vehicle?
5.
List three problems that can occur if the wheel lug nuts are not torqued to the proper specifications. A. B. C.
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AS1-L2-UXII TIRE BASICS
Directions Answer the following questions by writing all responses on this sheet. 1. Define the three basic tire components below. A. Beads
NAME:
DATE:
B.
Cord body
C.
Tread
2.
List the three basic types of cord body construction for passenger car tires? A. B. C.
3.
Define the following terms associated with tire ratings. A. Tread wear grade
B.
Speed rating
C.
Ply rating
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4. What is a tire's aspect ratio?
5.
A tire in the shop has a size of LT285/60R17. Describe the meaning of each component of the size below. A. B. C. D. E. LT 285 60 R 17
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JS1-L1-UXIII INSPECT AND INFLATE TIRES
Equipment: Pencil-type tire gauge Tread depth gauge Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Visually inspect each tire for wear or damage. Answer the questions below. Is the tread wear abnormal? Are there punctures? Are there lumps or knots? Are there exposed cords? Are the valve stems damaged? Are the valve stems missing? Are there flat spots? Are radial and bias tires on the same axle? Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No
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Do the tire sizes vary? Yes No For the questions answered "Yes," describe the problem and determine necessary actions in the space below. If abnormal tread wear is noted during the inspection, be sure to identify the cause.
5.
Spin each wheel-and-tire assembly while noting any wobble (lateral or radial runout). Record observations.
6.
Determine the proper inflation pressure for the vehicle. Record the pressures in the spaces. Lower the vehicle. Cold Inflation Pressure Front Tires Rear Tires Spare Tire
7.
Check and adjust the tire pressure, as needed. a. b. c. Remove the cap from the valve stem. Press the tire gauge on the stem to obtain the pressure reading. Compare the reading to the pressure recommended by the vehicle manufacturer. If the pressure is high, press the metal stem in the center of the valve to release air from the tire and recheck the pressure with the tire gauge. Repeat this step until the correct pressure is reached.
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If the pressure is low, add air and recheck the pressure with the tire gauge. Repeat this step until the correct pressure is reached.
d. e.
Reinstall the valve stem caps. If stem extensions are used, make sure they are in place.
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JS2-L1-UXIII ROTATE TIRES
DATE: NAME(S):
Equipment: Hand tools Personal protective equipment (PPE) Torque wrench Vehicle lifting equipment Wheel wrench Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3.
4.
Using service information, locate a procedure for rotating the tires in the correct pattern. Be sure to determine the lug nut torque sequence and the final torque specifications. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, rotate the vehicle's tires. a. Inspect the condition of the tires during the rotation. Record observations below.
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b. Inspect the condition of the wheel studs and lug nuts. Record observations below. Replace any defective wheel studs or lug nuts according to the instructor's directions.
c. 5. 6. 7.
Inflate all tires to the recommended pressure.
Clean dirt and corrosion from the wheel hub mounting area and from the center pilot hole of the wheel. Place each wheel on the hub and install the lug nuts finger-tight. Using the proper wrench, tighten the nuts alternately to draw the wheel evenly against the hub. a. If using an electric or pneumatic impact tool with torque sticks, tighten all lug nuts completely in an alternating pattern (or in a star pattern for five lug nuts). If tightening the lug nuts manually, lower the vehicle and finish tightening the lug nuts with a torque wrench to the manufacturer's specified torque rating.
b.
CAUTION: To prevent rotor distortion, do not use an air wrench to replace lug nuts on hubs with disc brakes. 8. Install the wheel covers. CAUTION: To prevent damage to the wheel covers during installation, hit the cover only around the outer circumference with a soft-faced rubber mallet. 9. If the wheels are equipped with a tire pressure monitoring system, perform the procedure to register the wheels with the system in their new location.
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JS1-L2-UXIII DISMOUNT, INSPECT, AND MOUNT TIRES
Equipment: Personal protective equipment (PPE) Tire changer Tire pressure gauge Valve core tool Wheel weight pliers Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3. 4. 5. 6.
If the wheel-and-tire assembly is on a vehicle, remove it from the vehicle. Remove the valve core to deflate the tire. Remove any wheel weights from the wheel. Mount the tire on the tire changer and dismount the tire according to the instructions of the manufacturer of the tire changer. CAUTION: Failure to follow manufacturer's instructions when operating a tire changer can result in serious personal injury. NOTE: In order to make bead removal easier and to prevent damage, apply a rubber lubricant to both beads before dismounting.
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7. Inspect the wheel and valve stem and answer the following questions. Is the rim damaged or bent? Are the rim bead seats rusted? Is the wheel broken or cracked? Is the valve stem in bad condition? Yes Yes Yes Yes No No No No
If "Yes" is the answer to any of the above questions, describe the necessary action to correct the problem. Write responses below.
8.
Using the procedure outlined below, inspect the tire that needs to be mounted. a. b. c. d. e. Inspect the beads. Replace the tire if the beads are badly torn. Check for any punctures in the tire. Patch repairable punctures before mounting. See JS3-L2-UXIII for this procedure. Check for wear or damage to the tire tread or sidewall. Discard defective tires. Check for and remove any foreign material from inside the tire. Record any problems in the space below.
9.
Clean the bead seating area of the rim before mounting the tire. Replace any defective tires, wheels, or valve stems according to the instructor's directions.
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10. Mount the tire on the wheel according to the manufacturer's instructions for the tire changer. a. Apply a rubber lubricant to both beads before mounting. CAUTION: Do not exceed 25 psi when popping the tire beads. Keep fingers clear of the tire when seating the bead on the rim. b. c. d. e. f. g. 11. 12. Inflate the tire to 40 psi to seat the beads after they popped. Install the valve core and adjust the tire pressure to the recommended pressure. Check for leaks at the valve core. Repair any leaks. Install the valve stem cap or extension. Check for leaks around both tire beads. Repair any leaks. Inspect the tire for uneven bead seating and correct as needed.
Rebalance the tire. Reinstall the wheel-and-tire assembly on the vehicle, if required.
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W 228

JS2-L2-UXIII DISMOUNT, INSPECT, AND MOUNT A TIRE ON A WHEEL EQUIPPED WITH A TIRE PRESSURE SENSOR
Equipment: Personal protective equipment (PPE) Tire changer Tire pressure gauge Valve core tool Wheel weight pliers Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3. 4. 5. 6.
If the wheel-and-tire assembly is on a vehicle, remove it from the vehicle. Remove the valve core to deflate the tire. Retain the valve core for reinstallation. Remove any wheel weights from the wheel. Using service information, locate a procedure for dismounting a tire on a wheel with a tire pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, mount the wheel-and-tire assembly on a tire changer and dismount the tire.
W 229
7. Inspect the wheel and valve stem and answer the following questions. Is the rim damaged or bent? Are the rim bead seats rusted? Is the wheel broken or cracked? Is the valve stem in bad condition? Yes Yes Yes Yes No No No No
If "Yes" is the answer to any of the above questions, describe the necessary action to correct the problem. Write responses below.
8.
Using the procedure outlined below, inspect the tire that needs to be mounted. a. b. c. d. e. Inspect the beads. Replace the tire if the beads are badly torn. Check for any punctures in the tire. Patch repairable punctures before mounting. See JS3-L2-UXIII for this procedure. Check for wear or damage to the tire tread or sidewall. Discard defective tires. Check for and remove any foreign material from inside the tire. Record any problems in the space below.
9.
Clean the bead seating area of the rim before mounting the tire. Replace any defective tires, wheels, or valve stems according to the instructor's directions. CAUTION: The valve stems used for tire pressure sensors are specially made for the sensors. Replacing the valve stems with types that are not designed for the system may cause the sensors to corrode and malfunction.
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CAUTION: Do not use a rubber sealant to install the new stem because sealant can clog the pressure sensor. NOTE: Some early tire pressure sensors are located in the center of the rim and do not use the valve stem as a part of the system. On those systems, the valve stems are serviced normally. 10. 11. Apply a rubber lubricant to both beads before mounting. Using service information, locate a procedure for mounting the tire on a wheel with a tire pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, mount the tire on the wheel. 12. Inflate the tire to 40 psi to seat the beads after they pop. CAUTION: Do not exceed 25 psi when popping the tire beads. Keep fingers clear of the tire when seating the bead on the rim. 13. Install the valve core and adjust the tire pressure to the recommended pressure. CAUTION: The valve cores used for tire pressure sensors are specially made for the sensors. Replacing the valve cores with types that are not designed for the system may cause the sensors to corrode and malfunction. 14. Install the valve stem cap or extension. CAUTION: The valve caps used for tire pressure sensors are specially made for the sensors. Replacing the valve caps with types that are not designed for the system may cause the sensors to corrode and malfunction. 15. 16. 17. Check for leaks around both tire beads. Repair any leaks. Inspect the tire for uneven bead seating and correct as needed. Rebalance the tire.
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18. Reinstall the wheel-and-tire assembly on the vehicle, if required.
W 232

JS3-L2-UXIII REPAIR PUNCTURES IN TUBELESS TIRES
DATE: NAME(S):
Equipment: Personal protective equipment (PPE) Tire buffer Tire changer Tire pressure gauge Tire-spreading tool Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
3. 4. 5. 6. 7.
If the wheel-and-tire assembly is on a vehicle, remove it from the vehicle. Locate and mark the puncture. Remove the foreign object causing the puncture. Dismount the tire. For this procedure, refer to JS1-L2-UXIII. Mount the tire in a tire-spreading tool and inspect the condition of the tire. Answer the questions below. Is the puncture repairable? Is the bead in good condition? Is the tire wear normal? Yes_____ No_____ Yes_____ No_____ Yes_____ No_____
Is the tire in good general condition? Yes_____ No_____
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If "No" is the answer to any of the above questions, describe the problem and determine necessary action. Record below.
8.
Determine the type of repair to make and record it. Consult the instructor for directions.
9. 10.
Probe the puncture to make sure all foreign material is removed. Using the procedure outlined below, repair the tire. a. b. c. d. e. Prepare the area that needs patching according to the type of patch that is used. Remove all buffing dust from the tire. Apply tire patch cement and allow it to dry thoroughly. Install the patch and bond the patch to the tire. Cut off the excess patch-plug, if used.
11. 12.
Mount the repaired tire on the wheel. For this procedure, refer to JS1-L2-UXIII. Test the repair for leaks. Record the results.
13. 14.
Balance the tire. Reinstall the wheel-and-tire assembly on the vehicle, if required.
W 234

JS4-L2-UXIII INSPECT, DIAGNOSE, AND CALIBRATE A TIRE PRESSURE MONITORING SYSTEM
Equipment: Personal protective equipment (PPE) Tire pressure gauge Tire changer Magnet tool for tire pressure monitoring system Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Check the accuracy of the tire pressure monitoring system by performing the following steps on each wheel. a. b. Check the air pressure in the tire with an air gauge that is known to be accurate and compare the reading to the one from the system. If the gauge and system readings do not match within specifications, reregister the wheel with the system and perform step 3a again. If the gauge and system readings still do not match, replace the tire pressure sensor.
4.
Using service information, locate a procedure for dismounting a tire on a wheel with a tire pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, mount the wheel-and-tire assembly on a tire changer and dismount the tire.
W 235
5. Using service information, locate a procedure for replacing the tire pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, B.)
Using the procedure, replace the tire pressure sensor. 6. Using service information, locate a procedure for mounting a tire on a wheel with a tire pressure sensor. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, mount the tire on the wheel. 7. 8. 9. Rebalance the tire. Install the wheel-and-tire assembly on the vehicle. Using service information, locate a procedure for calibrating a tire pressure monitoring system. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section V, F.)
Using the procedure, calibrate the system. 10. Use an accurate gauge to recheck the air pressure in each tire and ensure that the readings match those from the tire pressure monitoring system within specifications.
W 236

AS1-L3-UXIII WHEEL BALANCE AND RUNOUT
Directions Answer the following questions by writing all responses on this sheet. 1. What is the term that is used to describe a wheel-and-tire assembly that is heavier at one point than another?
NAME:
DATE:
2.
What are two disadvantages of an imbalanced wheel-and-tire assembly? A. B.
3.
Define the following terms associated with wheel-and-tire assemblies. A. Static balance
B.
Dynamic balance
4.
What is a sign that a wheel-and-tire assembly has radial runout?
5.
What is a sign that a wheel-and-tire assembly has lateral runout?
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W 238

JS1-L4-UXIII MEASURE A WHEEL-AND-TIRE ASSEMBLY FOR RADIAL AND LATERAL RUNOUT
Equipment: Runout gauge Tire changer Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
After obtaining permission from the instructor, drive the vehicle to warm the tires and eliminate flat spots. CAUTION: Drive the vehicle only with the instructor's approval.
4.
Use proper lifting equipment to raise the vehicle. Make sure the tires are raised 3 in to 4 in off the floor. CAUTION: When lifting a vehicle, always use proper lifting equipment and observe all safety precautions.
5. 6.
Check and correct wheel bearing adjustment, when applicable. Using service information, locate a procedure for determining the maximum allowable radial and lateral runout for the wheel-and-tire assembly. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
W 239
Maximum radial runout Maximum lateral runout 7. ________________ ________________
Test radial runout of the wheel-and-tire assembly. a. b. c. Position a runout gauge on the center rib of the tire. Rotate the wheel one full revolution. Zero the runout gauge at the low spot of the wheel-and-tire assembly. Rotate the wheel again and mark the high spot on the tread. Also mark the wheel bolt nearest the high spot. Record runout below. Compare runout to the specification recorded in step 6 of this job sheet. If runout is within acceptable limits, go to step 10 of this job sheet. If runout is not within acceptable limits, go to step 8. Radial runout
8.
Unbolt the wheel and rotate it two studs on the hub. Repeat steps 7 a, b, and c above. If runout is still excessive, mark the location of the high spot. Answer the questions below. a. Is the new mark near the high spot marked in c of step 7 above? YES b. NO
Does the new mark line up with the wheel stud mark? YES NO
c.
Based on the results of step 8, indicate below which corrective procedures, if any, should be performed.
Corrective action needs to be taken. YES NO
Match mounting should be performed. YES NO
NOTE: If match mounting must be performed, proceed to step 9.
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9. Using the procedure outlined below, match mount the wheel-and-tire assembly. a. b. c. d. e. Mark the runout high spot on the wheel and tire. Using a tire changer, deflate the tire and break the beads loose. Measure the lateral and radial runout of the wheel. If the wheel is defective, replace it. Rotate the tire on the rim 180 from its original position. Inflate the tire to the specified pressure. Install the wheel on the vehicle and recheck the runout. If runout is within specifications, proceed with balancing the tire. If runout is still excessive, the tire must be replaced. Record the results of the match mounting procedure below.
f.
10.
Test the wheel-and-tire assembly for lateral runout. a. b. c. Place the runout gauge on the tire sidewall as close to the tire shoulder as possible. Rotate the wheel one revolution. Mark the low spot on the tire and zero the gauge. Rotate the tire again. Mark the high spot on the tire. Also mark the lug bolt nearest the high spot. Record the lateral runout in the space below. Lateral runout d. Compare the lateral runout recorded above to the specification recorded in step 6 of this job sheet. If runout is within specification, this job sheet is complete. If runout is not within specification, go to step 11.
W 241
11. Unbolt the wheel and align the low spot mark with the marked wheel stud. Repeat steps 10 a, b, and c. If runout is still excessive, mark the position of the high spot and answer the questions below. a. Is the marked wheel stud near the low spot marked in b of step 10? YES b. NO
Is the marked wheel stud near the high spot marked in c of step 10? YES NO
c.
Answer the following questions based on the answers to questions a and b above. Should the tire and wheel be match mounted? If so, refer to step 9. YES NO
Should the hub or hub assembly be repaired or replaced? YES NO
W 242

JS2-L4-UXIII BALANCE WHEEL-AND-TIRE ASSEMBLIES
Equipment: Static/dynamic wheel balancer Wheel weight pliers Personal protective equipment (PPE) Vehicle lifting equipment Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION
NAME(S):
DATE:
3.
4.
Test the lateral and radial runout of the wheel-and-tire assembly to be balanced. (Refer to JS1-L4-UXIII.) Record the test results and compare them to the tire and wheel runout specifications recorded in step 6 of JS1-L4-UXIII. Is the tire and wheel runout within specifications? YES_____ NO______ NOTE: Excessive tire and wheel runout should be corrected before attempting to balance the tires. Consult the instructor if excessive runout is found.
5.
Inspect tire condition. Record any excessive wear or defects below.
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6. 7. Remove the wheel-and-tire assembly from the vehicle. Balance the wheel-and-tire assembly according to the instructions provided by the manufacturer of the balancer. Be sure to include the steps below in the balancing procedure. a. b. c. d. 8. Remove any pebbles or foreign material lodged in the tire tread and wheel assembly. Remove old wheel weights. Install weights securely. Recheck balance after weights are installed.
Reinstall the wheel-and-tire assembly on the vehicle. Tighten the lug nuts to the specified torque. Lower the vehicle.
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AS1-L1-UXIV STEERING, SUSPENSION, AND WHEEL ALIGNMENT CONCERNS
Directions Answer the following questions by writing all responses on this sheet. 1. Answer the following questions about wheel shimmy. A. Name two characteristics of wheel shimmy. B. Name five causes of wheel shimmy. 2. What two variables affect the noise that damaged wheel bearings make? A. B. 3. Answer the following questions about lateral pull. A. Describe the two types of lateral pull.
NAME:
DATE:
W 245
B. Name four causes of lateral pull. 4. What term is used to describe the failure of the steering wheel to return to the straight-ahead position after a turn?
5.
When road testing a vehicle for lateral pull, what type of surface should the vehicle be driven on?
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JS1-L1-UXIV DIAGNOSE VARIOUS STEERING, SUSPENSION, AND WHEEL ALIGNMENT CONCERNS
Equipment: Notebook Pen Personal protective equipment (PPE) Procedure: CAUTION: Always obtain the instructor's approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time. 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Use the procedure outlined below to road test the vehicle for shimmy. a. b. c. Slowly drive the vehicle in a straight line and observe for shimmy. Slowly accelerate to highway speed while noting any shimmy. Have an assistant record the results of the shimmy test.
4.
Use the procedure outlined below to road test the vehicle for vibration. a. b. Drive the vehicle at highway speed and note any vibrations. Vary the speed and note if the vibration increases, decreases, or changes in quality.
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c. If vibration is noted, drive past the speed at which the vibration occurs, release the accelerator, and carefully slip the transmission selector into neutral. If the vibration stops, the problem is likely in the driveline. Coast down through the speed where the vibration occurs and note whether it stops or changes. Have an assistant record the results of the vibration test.
d. e. 5.
Use the procedure outlined below to road test the vehicle for wander. a. b. Relax hands on the steering wheel while driving straight. If the vehicle leads to one side, correct the steering and note if the vehicle leads to the other side. If the vehicle constantly needs correcting to the right and left, the problem is wander. NOTE: If the vehicle leads to the same side after every correction, the problem is lateral pull. The test for lateral pull is described below in step 6. c. If wander or lateral pull is detected, drive the vehicle on different road surfaces to make sure that an irregular road surface is not causing the problem. Have an assistant record the results of the wander test.
d. 6.
Use the procedure outlined below to road test the vehicle for lateral pull. a. Drive the vehicle on a flat, level surface and note any lateral pull. The characteristic of lateral pull is the vehicle leads in the same direction. If pull is detected, drive the vehicle on a variety of road surfaces to make sure a particular surface is not pulling the vehicle. Carefully apply the brakes to see if the pull occurs only when braking. Have an assistant record the results of the lateral pull test.
b. c. d.
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7. Use the procedure outlined below to road test the vehicle for hard steering or poor steering return. a. b. Drive the vehicle on a flat, level surface and make several turns to both the left and the right. Note if the effort required to steer the vehicle is excessive. Note if the steering returns to the straight-ahead position when the vehicle is coming out of a turn. Have an assistant record the results of the steering test.
c. 8.
Use the procedure outlined below to road test the vehicle for wheel bearing noise. a. Drive the vehicle at a slow speed and steer it from side to side in order to load the wheel bearings on both sides of the vehicle. Listen for bearing noise. Note any increase in noise. If noise is heard, note which wheel the noise is coming from. If there is a bearing noise, drive on different types of road surfaces to eliminate road surface conditions as a source of the noise. Have an assistant record the results of the bearing noise test.
b.
c. 9.
If any problems are detected during the road test, diagnose what the problems might be. Record the diagnosis below. NOTE: Use a diagnostic chart from the appropriate service information to aid in diagnosis.
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W 250

AS1-L2-UXIV WHEEL ALIGNMENT PRINCIPLES
Directions Answer the following questions by writing all responses on this sheet. 1. Answer the following questions about camber? A. What is camber?
NAME:
DATE:
B.
What are two purposes of camber?
2.
Answer the following questions about caster? A. What is caster?
B.
What are two purposes of caster?
W 251
3. Answer the following questions about toe. A. What is toe?
B.
What is the difference between toe-in and toe-out?
4.
What are two indications that a vehicle has an incorrect thrust angle? A. B.
5.
What measurement should be taken and corrected before any alignment adjustment is made?
W 252

JS1-L3-UXIV MEASURE AND CORRECT FRONT-WHEEL ALIGNMENT
Equipment: Alignment machine Hand tools Personal protective equipment (PPE) Special tools as needed Vehicle lifting equipment Procedure: 1. Wear PPE while performing all procedures on this job sheet. NOTE: If the vehicle requires a four-wheel alignment, adjust the rear wheels first. 2. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Perform a prealignment check of the vehicle. Use the checklist below to indicate if the condition of an item is "OK" or "Not OK." Tire pressure Tire sizes Wheel bearing adjustment Steering and suspension components Wheel-and-tire assembly runout Steering gear adjustment OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK
W 253
Vehicle load Ball joints OK OK Not OK Not OK
If any item in the previous list is "Not OK," describe the problem and determine necessary action in the space below.
NOTE: If there are worn or loose parts, replace them to ensure an accurate alignment. Inform the instructor if worn parts are discovered during the prealignment inspection. 5. Using service information, locate a procedure for measuring front-wheel alignment angles in the proper sequence. List all angles that the alignment equipment is capable of measuring. Record the specifications for each angle. Also record the vehicle's ride height specifications. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Measure the vehicle ride height and compare it to the specifications recorded in the above procedure. Is the vehicle at proper ride height? Yes No
NOTE: Incorrect ride height results in incorrect alignment. If the ride height is incorrect, consult the instructor before continuing. 6. Using the sequence developed in step 5 of this job sheet, measure the camber and caster. Record the measurements below. Left Camber Caster Right
_________________________ _________________________
W 254

7. Using service information, locate a procedure for adjusting the front-wheel caster. Include any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, adjust the front-wheel caster to specifications. Record observations below.
8.
Using service information, locate a procedure for adjusting the front-wheel camber. List any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Using the procedure, adjust the front-wheel camber to specifications. Record observations below.
9.
Measure the toe and record measurements below.
10.
Using service information, locate a procedure for adjusting the front-wheel toe. List any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VI.)
W 255
Using the procedure, adjust front-wheel toe to specifications. Record observations below.
11.
Record any angles that could not be adjusted to specifications. In the space below, indicate what problem may be preventing proper adjustment.
W 256

JS2-L3-UXIV MEASURE AND CORRECT REAR-WHEEL ALIGNMENT
Equipment: Alignment machine Hand tools Personal protective equipment (PPE) Special tools as needed Vehicle lifting equipment Procedure: 1. Wear PPE while performing all procedures on this job sheet. NOTE: If the vehicle requires a four-wheel alignment, adjust the rear wheels first. 2. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
EVALUATION NAME(S):
DATE:
3.
4.
Perform a prealignment check of the vehicle. Use the checklist below to indicate if the condition of an item is "OK" or "Not OK." Tire pressure Tire sizes Wheel bearing adjustment Suspension components Wheel-and-tire assembly runout Steering gear adjustment OK OK OK OK OK OK Not OK Not OK Not OK NOT OK Not OK Not OK
W 257
Vehicle load Ball joints OK OK Not OK Not OK
If any item in the list is "Not OK," describe the problem and determine necessary actions in the space below.
NOTE: If worn or loose parts are found, replace them to ensure an accurate alignment. Inform the instructor if worn parts are discovered during the prealignment inspection. 5. Using service information, locate a procedure for measuring rear-wheel alignment angles. Record the specifications for each angle. Also record the vehicle's ride height. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure.
Measure the vehicle ride height and compare it to the specifications from the procedure above. Is the vehicle at proper ride height? Yes _____ No _____
NOTE: Incorrect ride height results in incorrect alignment. If the ride height is incorrect, consult the instructor before continuing. 6. Using the sequence developed in step 5, measure all rear-wheel alignment angles. Record the measurements below. Left Right
Camber _________________________ Caster Toe _________________________ _________________________
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7. Using service information, locate a procedure for adjusting the rearwheel caster. List any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VII, B.)
Using the procedure, adjust the rear-wheel caster to specifications. Record observations below.
8.
Using service information, locate a procedure for adjusting the rear-wheel camber. List any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VII, B.)
Using the procedure, adjust the rear-wheel camber to specifications. Record observations.
9.
Using service information source, locate a procedure for adjusting the rear-wheel toe. List any special tools required. Make sure the procedure is appropriate for the make and model of the vehicle. Have the instructor check the box to approve the procedure. (For a general procedure, see Section VII, B.)
W 259
Using the procedure, adjust the rear-wheel toe to specifications. Record observations.
10.
Check the vehicle thrust angle if the alignment equipment allows for it. Record the results below.
11. 12.
Recheck all angles. Correct any angles that still do not meet specifications. Record any angles that could not be adjusted to specifications. In the space below, indicate what problem may be preventing proper adjustment.
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JS3-L3-UXIV DIAGNOSE ALIGNMENT CONCERNS CAUSED BY DAMAGED COMPONENTS
Equipment: Personal protective equipment (PPE) Vehicle lifting equipment Alignment equipment Hand tools Tape measure Tram gauge Brake pedal depressor NOTE: Perform the procedures in this job sheet if the alignment is still incorrect after performing the normal alignment procedures in JS1-L3-UXIV and JS2-L3-UXIV. Procedure: 1. 2. Wear PPE while performing all procedures on this job sheet. Research applicable vehicle service information such as vehicle service history, VIN, certification labels, and calibration decals. Record the necessary information in the following space.
NAME(S):
DATE:
EVALUATION
3.
Perform a road test to confirm the concern. Record observations below. CAUTION: Always obtain the instructor's approval before conducting a road test. Conduct the road test in an area with little or no traffic. Never exceed the legal speed limit during the road test. Always wear safety belts. An assistant should record all observations made during the road test. Do not attempt to drive and record results at the same time.
W 261
4. Position the vehicle on the alignment equipment and perform the prealignment inspection. Use the checklist below to indicate if the condition of an item is "OK" or "Not OK." Tire pressure Tire sizes Wheel bearing adjustment Steering and suspension components Wheel-and-tire assembly runout Steering gear adjustment Vehicle load Ball joints OK OK OK OK OK OK OK OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK Not OK
If any item in the previous list is "Not OK," describe the problem and determine necessary action in the space below.
5. 6.
Check alignment settings and compare them to specifications. Make any necessary adjustments. Measure the vehicle's wheelbase to check for front wheel setback. a. b. Steer the wheels so that they are straight ahead. On the right side of the vehicle, use a tram gauge to measure from the center of the front wheel to the center of the rear wheel. Record the measurement below.
c.
Repeat the measurement on the left side of the vehicle. Record the measurement below.
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d. Compare these measurements and note any difference from side to side. Determine the necessary action and record below.
7.
Using service information, locate specifications for engine cradle measurements and alignment. Make sure the specifications are appropriate for the make and model of the vehicle. Have the instructor check the box to approve the specifications.
8.
9.
Perform the following steps to check engine cradle alignment. a. Remove any components that are blocking access to the cradle mounting points. NOTE: Clean dirt and debris from all measurement points to ensure accurate measurements. b. Perform diagonal measurements from the vehicle's center point (or manufacturer's designated position) to each of the engine cradle mounting points. Record the measurements below.
10.
To check for cradle damage or distortion, perform the following measurements. a. Perform width measurements of engine cradle mounting points at the front and back of the cradle. Record the measurements below.
W 263
b. Perform length measurements of engine cradle mounting points at both sides of the cradle. Record the measurements below.
c.
Perform diagonal measurements of engine cradle mounting points. Record the measurements below.
11.
Compare all measurements to specifications to determine if the cradle is damaged or misaligned. a. b. c. If the cradle is damaged, the cradle will need to be straightened or replaced. If the cradle is misaligned, loosen all cradle mounting bolts, move the cradle to the correct position, and retighten the mounting bolts. Determine the necessary action and record below.
12.
Position the vehicle on the alignment equipment to measure the steering axis inclination (SAI) and included angle. NOTE: Some types of computerized alignment equipment provide SAI and included angle readings as part of the camber and caster measurement. a. b. c. d. e. Start at the left front wheel. Lock the front brakes using a brake pedal depressor. Steer the wheels straight ahead. Steer the wheels to the left until the indicator is aligned (normally about 20 left). Steer the wheels to the right until the indicator is aligned (normally about 20 right).
W 264

f. Record the SAI and included angle readings in the space below.
g.
Repeat the procedure for the right front wheel. Record the readings below.
h.
Compare the SAI and included angle readings to specifications. Determine the necessary action and record below.
13.
Check the vehicle's turning radius (toe-out on turns). NOTE: Ensure that the front-wheel toe setting is correct before checking the turning radius. a. b. Steer the wheels straight ahead. Steer the wheels to the left until the left front wheel is at 20. Record the reading below.
c.
Steer the wheels to the right until right front wheel is at 20. Record the reading below.
d.
Compare the readings to specifications. Determine the necessary action and record below.
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70-1805-W 10-1831-T

Module 5: Steering and Suspension Systems

Automotive Technology Curriculum

2006 2005 Edition Student Test Workbook Packet

STEERING AND SUSPENSION SYSTEMS

Automotive Technology Module 5: Steering and Suspension Systems Student Workbook

Project Coordinator: Erica Kassel

Editor: Janis Levsen

Graphic Artists: Chris Benedict Jacqueline Craig

STEERING AND SUSPENSION SYSTEMS

JS5-L2-UIV JS1-L3-UIV JS2-L3-UIV JS1-L1-UV

261262 267268 269270 287290

W 7576 W 7778 W 7980 W 8184

STEERING AND SUSPENSION SYSTEMS

JS1-L3-UVI JS2-L3-UVI JS3-L3-UVI

369370 371372 373374

W 107108 W 109110 W 111112

STEERING AND SUSPENSION SYSTEMS

STEERING AND SUSPENSION SYSTEMS

STEERING AND SUSPENSION SYSTEMS

Vehicle Service History Information:

Related Technical Service Bulletins:

Diagnostic Procedures Performed:

Labor Procedures and Costs

Outside Labor Procedures and Costs

Total Labor Costs Parts Costs Quantity Part # Description

STEERING AND SUSPENSION SYSTEMS

STEERING AND SUSPENSION SYSTEMS

Determine the necessary action and record in the following space.

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Rack-and-pinion steering system

What type of design is commonly used in manual steering gears?

STEERING AND SUSPENSION SYSTEMS

How does Pascals law apply to the power steering system?

What are the three common types of power steering pumps? A. B. C.

STEERING AND SUSPENSION SYSTEMS

How does the proportional rack-and-pinion steering system operate?

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Determine and record the type of power steering fluid used.

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Define the term steering play.

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

STEERING AND SUSPENSION SYSTEMS

Lower the vehicle.

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

STEERING AND SUSPENSION SYSTEMS

Inspect the flexible coupling for wear or damage. Record observations.

STEERING AND SUSPENSION SYSTEMS

Average of the above evaluations

Is there fluid leakage during damper travel? Yes _ No ___