A4 Suspension and Steering Test
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TABLE OF CONTENTS Chapter 1 – Suspension and Steering Test A4 Overview .............................. 1 Overview of Chapter One ......................................................................................... 1 The Objectives .......................................................................................................... 1 An Introduction to the AudioLearn Suspension and Steering Study Guide ........... 2 An Overview of the Suspension and Steering Test A4 ............................................ 3 The Four Question Formats of the ASE Suspension and Steering Certification Exam ................................................................................................... 3 Except Question Format .......................................................................................... 4 Technician A… Technician B Question Format ....................................................... 4 Most Likely Question Format .................................................................................. 5 Least-Likely Question Format ................................................................................. 6 Introducing the Content Structure of the Suspension and Steering Certification Program............................................................................................... 7 Chapter 2: Steering Systems Diagnosis and Repair ....................................17 An Overview of Chapter Two ..................................................................................17 The Objectives .........................................................................................................17 An Overview of the Steering System ...................................................................... 18 Understanding How the Steering System Operates .............................................. 20 Understanding the Differences between the Rack and Pinion System and the Parallelogram System ...................................................................................... 22 Understanding Steering Geometry ........................................................................ 23 Summary ................................................................................................................ 26 Key Takeaways ....................................................................................................... 27 1
Task A.1.5: Diagnose steering gear (non-rack and pinion type) noises, binding, vibration, free play, steering effort, steering pull, and leakage concerns; determine the needed repairs ............................................................... 51 Task A.1.6: Diagnose Rack and Pinion steering Gear Noises, binding, vibrations, free play, steering effort, steering pull, and leakage concerns: determine the needed repairs ................................................................................ 54 Task A.1.7: Inspect Power Steering Fluid Level and condition; determine fluid type, and adjust fluid level in accordance with vehicle manufacturers’ recommendations................................................................................................... 56 Task A.1.8: Inspect, Adjust, Align, and replace power steering pump belts, tensioners and pulleys............................................................................................ 59 Task A.1.9: Diagnose Power Steering Pump Noise, Vibration, and fluid leakage; determine the needed repairs .................................................................. 62 Task A.1.10: Remove and replace power steering pump; inspect pump mounting and attaching brackets; remove and replace power steering pump pulley, transfer related components............................................................ 64 Task A.1.11: Perform power steering system pressure and flow tests; determine the needed repairs ................................................................................ 66 Task A.1.12: Inspect and replace power steering hoses, fittings, O-rings, coolers, and filters .................................................................................................. 68 Task A.1.13: Remove and replace steering gear (non-rack and pinion) type ........ 70 Task A.1.14: Remove and replace rack and pinion steering gear; inspect and replace mounting bushings and brackets ....................................................... 72 Task A.1.15: Adjust Steering gear (non-rack and pinion type) worm bearing preload and sector lash .......................................................................................... 75 Task A.1.16: Inspect and Replace steering gear (non-rack and pinion type) seals and gaskets .................................................................................................... 77 Task A.1.17: Adjust Rack And Pinion Steering Gear.............................................. 79
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Task A.1.18: Inspect and Replace rack and pinion steering gear bellows or boots .......................................................................................................................80 Task A.1.19: Flush, fill, and bleed power steering system ..................................... 82 Task A.1.20: Diagnose, inspect, repair or replace components of variableassist and variable ratio systems............................................................................ 83 Task A.1.21: Diagnose, inspect, adjust, repair or replace components (including sensors, motors, switches, actuators, harness, and control units) of rack mounted, electronically controlled, hydraulically and electrically assisted steering systems; initialize systems as required ................... 86 Summary ................................................................................................................ 87 Key Takeaways ....................................................................................................... 88 Sample Questions for Chapter Four ...................................................................... 90 Chapter 5: Suspension and Steering – Steering Linkage ............................ 93 An Overview of Chapter five .................................................................................. 93 Objectives of Chapter Five ..................................................................................... 93 Task A.1.22: Inspect and Adjust (where necessary) front and rear steering linkage geometry (including parallelism and vehicle ride height) ........................ 94 Task A.1.23: Inspect and Replace the Pitman Arm ............................................... 97 Task A.1.24: Inspect and Replace Center Link (rely link, drag link, and intermediate rod) ................................................................................................... 98 Task A.1.25: Inspect, adjust (where needed), and replace idler arm and mountings............................................................................................................. 100 Task A.1.26: Inspect, replace, and adjust tie rods, tie rod sleeves, adjusters, clamps, and tie rod ends (sockets and bushings) ................................................ 102 Task A.1.27: Inspect and Replace Steering Linkage Dampers ............................ 104 Summary .............................................................................................................. 106 Key Takeaways ..................................................................................................... 107 4
Sample Questions for Chapter Five ..................................................................... 108 Chapter 6: Suspension Systems Diagnosis and Repair – Front Suspensions ................................................................................................................ 112 An Overview of Chapter Six .................................................................................. 112 Task B.1.1: Diagnose front suspension system noises, handling, ride height, and ride quality concerns; determine needed repairs.............................. 114 Suspension System Principles ................................................................................... 114 Suspension System Components .......................................................................... 119 Types of Suspension Systems .............................................................................. 120 Active and Adaptive Suspension Systems ........................................................... 123 Task B.1.2: Inspect and replace upper and lower control arms, bushings, and shafts ..............................................................................................................127 Task B.1.3: Inspect and replace rebound and jounce bumpers........................... 129 Task B.1.4: Inspect, adjust, and replace track bar, strut rods, radius arms, and related mounts and bushings. ....................................................................... 130 Task B.1.5: Inspect and replace upper and lower ball joints (with or without wear indicators) ...................................................................................... 132 Task B.1.6: Inspect non-independent front axle assembly for damage and misalignment ........................................................................................................ 134 Task B.1.7: Inspect and replace front steering knuckle, spindle assemblies, and steering arms ................................................................................................. 135 Task B.1.8: Inspect and replace front suspension system coil springs and spring insulators or silencers ................................................................................137 Task B.1.9: Inspect and replace front suspension system leaf springs, leaf spring insulators, brackets, shackles, bushings, center pins, bolts, and mounts .................................................................................................................. 139
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Task B.1.10: Inspect, replace, and adjust front suspension system torsion bars and mounts .................................................................................................... 141 Task B.1.11: Inspect and replace front stabilizer bar or sway bar bushings, brackets, and links ............................................................................................... 143 Task B.1.12: Inspect and replace front strut cartridge or assembly .................... 145 Task B.1.13: Inspect and replace front strut bearings and mount ...................... 147 Task B.1.14: Inspect and replace shock absorbers, mounts, and bushings ......... 148 Task B.1.15: Diagnose and service front wheel bearings and hub assemblies .... 152 Task B1.16: Diagnose, inspect, adjust, repair or replace components (including sensors, switches, actuators, harnesses, and control units) of electric, hydraulic, and pneumatically controlled suspension systems .............. 153 Task B.1.17: Inspect and repair front cross-member and sub-frame mountings, bushings, brackets, and bolts. .......................................................... 154 Summary .............................................................................................................. 156 Key Takeaways ......................................................................................................157 Sample Questions for Chapter Six ....................................................................... 159 Chapter 7: Rear Suspension .................................................................... 163 An Overview of Chapter Seven............................................................................. 163 Objectives of Chapter Eight ................................................................................. 163 Task B.1.18: Diagnose rear suspension system noises, handling, ride height and ride quality concerns; determined needed repairs ....................................... 165 Task B.1.19: Inspect and replace rear suspension system coil springs and spring insulators (silencers)................................................................................. 166 Task B.1.20: Inspect and replace rear suspension system lateral links and arms (Track bars), control (trailing) arms, stabilizer bars (sway bars), bushings and mounts. .......................................................................................... 167
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Task B.1.21: Inspect and replace rear suspension system leaf spring, leaf spring insulators (silencers), shackles, brackets, bushings, center pins or bolts, and mounts ................................................................................................. 168 Task B.1.22: Inspect and replace rear rebound and jounce bumpers ................. 169 Task B.1.23: Inspect and replace rear strut cartridge or assembly and upper mount assembly ......................................................................................... 170 Task B.1.24: Inspect non-independent rear-axle assembly for damage and misalignment ......................................................................................................... 171 Task B.1.25: Inspect and replace rear ball joints and tie rod and toe link assemblies .............................................................................................................172 Task B.1.26: Inspect and replace rear knuckle or spindle assembly. ...................173 Task B.1.27: Inspect and replace shock absorbers, mounts, and bushings ........ 174 Task B.1.28: Diagnose and service rear wheel bearings and hub assemblies ......175 Task B.1.29: Diagnose, inspect, adjust, repair or replace components (including sensors, switches, actuators, harnesses, and control units) of electric, hydraulic, and pneumatically controlled suspension systems .............. 176 Task B.1.30: Inspect and repair rear (cross-member, sub-frame) mountings, bushings, brackets, and bolts ............................................................ 177 Summary .............................................................................................................. 178 Key Takeaways ..................................................................................................... 179 Sample Questions for Chapter Eight ................................................................... 180 Chapter 8: Wheel Alignment Diagnosis, Adjustment and Repair ............. 183 An Overview of Chapter eight .............................................................................. 183 The Objectives of Chapter eight ........................................................................... 183 Task C.1: Diagnose Vehicle wander, drift, pull, hard steering, bump steer (toe curve), memory steer, torque steer, and steering return concerns: determine the needed repairs. ............................................................................. 184 7
Key Takeaways .....................................................................................................204 Sample Questions for Chapter Eight ...................................................................206 Chapter 9: Wheel and Tire Diagnosis and Services .................................. 209 An Overview of Chapter nine ...............................................................................209 The Objectives of Chapter Nine ...........................................................................209 Task D.1: Diagnose tire wear patterns; determine needed repairs ..................... 210 Wheel and Tire Principles ........................................................................................ 210 Tire Wear Patterns ................................................................................................... 212 Task D.2: Inspect tire conditions, size, and application (load and speed ratings) ................................................................................................................. 213 Task D.3: Measure and adjust tire air pressure................................................... 215 Task D.4: Diagnose wheel and tire vibrations, shimmy, and noise concerns; determine the needed repairs ............................................................. 216 Task D.5: Rotate tires or wheels and torque fasteners according to manufacturer’s recommendations ........................................................................217 Task D.6: Measure wheel, tire, axle flange, and hub run-out (radial and lateral); determine the needed repairs ................................................................ 218 Task D.7: Diagnose tire pull (lead) problems; determine the corrective actions .................................................................................................................. 219 Task D.8: Dismount and mount tire on wheel ....................................................220 Task D.9: Balance wheel and tire assembly ......................................................... 221 Task D.10: Test and diagnose direct and indirect tire pressure monitoring systems; determine the needed repairs; perform system relearn as required. ............................................................................................................... 222 Summary .............................................................................................................. 223 Key Takeaways: .................................................................................................... 224
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Sample Questions for Chapter Nine .................................................................... 225 Practice Test for the Steering and Suspension Test ................................. 228
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Suspension Systems
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Diagnosis and Repair: 1. Front Suspension 2. Rear Suspension Wheel Alignment, Diagnosis, Adjustment, and Repairs Wheel and Tire Diagnosis and Service Total
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SUMMARY Chapter one was an introduction for candidates to the fourth test in the Automotive Service Excellence Program. The Suspension and Steering test is made up of four test specifications with multiple task lists assigned to each. Throughout this AudioLearn study guide, these test specifications will form the basis of the chapters according to the ASE program. Finally, the ASE certification program provides a one hour testing duration for the Suspension and Steering test. That means you will have to answer all the questions in your booklet in just one hour.
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mechanical build of the parallelogram system also makes it a good fit for heavier vehicles such as trucks.
UNDERSTANDING STEERING GEOMETRY The concept known as steering geometry is defined by the relationship between the steering system, the wheel position and the suspension system. The geometrical arrangement of the steering system is made up of steering linkages that determine the proper orientation of a vehicle’s wheels. In general, as the wheel moves up and down in relation to the vehicle’s body, the steering linkage should swing vertically through an arc. Please refer to the AudioLearn Study guide PDF file to view figure 2.3. In this figure, the steering geometry of a rack and pinion steering system is shown.
Figure 2.3
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Steering geometry also determines how well or seamlessly a vehicle goes through turns. For example, when rounding a corner, steering geometry ensures that the inner and outer wheel trace circles with different paths. The inside wheel does not travel as far as the outside wheel. This ensures a smooth turn. Without the proper geometry, the vehicle’s tires will be dragged across the road and this phenomenon is known as ‘scrubbing’. There are a couple of steering geometry principles currently being used to orientate the steering system and wheel orientation of a vehicle. The Ackerman principle is one principle example and in Figure 2.4 you will see a visual representation of how the Ackerman principle functions.
Figure 2.4
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