Professional Documents
Culture Documents
Service Suspension System
Service Suspension System
Service Suspension System
Sector:
AUTOMOTIVE
Qualification:
Automotive Servicing NC II
Unit of Competency:
Service Suspension System
Module Title:
12. Provide work skill instructions 12. Providing work skill instructions ALT311209
13. Identify and select original Identifying and selecting original ALT723210
automotive parts and products automotive parts and products
8. Service Differential and Front Axle Servicing Differential and Front ALT723311
Axle
9. Service steering system Servicing Steering system ALT723312
The unit of competency "Service Suspension System" contains knowledge, skills and
attitudes required for an Automotive Servicing. It is one of the specialized modules at
National Certificate level (NC II).
You are required to go through a series of learning activities in order to complete each
learning outcome of the module. In each learning outcome are Information Sheets and
Resources Sheets (Reference Materials for further reading to help you better understand the
required activities). Follow these activities on your own and answer the self-check at the end of
each learning outcome. You may remove a blank answer sheet at the end of each module (or
get one from your facilitator/trainer) to write your answers for each self-check. If you have
questions, don’t hesitate to ask your facilitator for assistance.
If you can demonstrate to your trainer that you are competent in a particular skill or skills,
talk to him/her about having them formally recognized so you don't have to do the same training
again. If you have a qualification or Certificate of Competency from previous trainings, show it
to your trainer. If the skills you acquired are still current and relevant to the unit/s of competency
they may become part of the evidence you can present for RPL. If you are not sure about the
currency of your skills, discuss this with your trainer.
At the end of this module is a Learner’s Diary. Use this diary to record important dates, jobs
undertaken and other workplace events that will assist you in providing further details to your
trainer or assessor. A Record of Achievement is also provided for your trainer to complete
once you complete the module.
This module was prepared to help you achieve the required competency in servicing
suspension system. This will be the source of information for you to acquire knowledge and
skills in this particular trade independently and at your own pace, with minimum supervision or
help from your instructor.
Talk to your trainer and agree on how you will both organize the Training of this unit.
Read through the module carefully. It is divided into sections, which cover all the skills,
and knowledge you need to successfully complete this module.
Work through all the information and complete the activities in each section. Read
information sheets and complete the self-check. Suggested references are included to
supplement the materials provided in this module.
Most probably your trainer will also be your supervisor or manager. He/she is there to
support you and show you the correct way to do things.
Your trainer will tell you about the important things you need to consider when you are
completing activities and it is important that you listen and take notes.
You will be given plenty of opportunity to ask questions and practice on the job. Make
sure you practice your new skills during regular work shifts. This way you will improve
both your speed and memory and also your confidence.
Use the self-check questions at the end of each section to test your own progress.
When you are ready, ask your trainer to watch you perform the activities outlined in this
module.
As you work through the activities, ask for written feedback on your progress. Your
trainer keeps feedback/ pre-assessment reports for this reason. When you have
successfully completed each element, ask your trainer to mark on the reports that you
are ready for assessment.
When you have completed this module (or several modules), and feel confident that you
have had sufficient practice, your trainer will arrange an appointment with registered
assessor to assess you. The results of your assessment will be recorded in your
competency Achievement Record.
Qualification : Automotive Servicing NC II
Introduction :
This module covers the skills and knowledge in diagnosing suspension system failure,
dismounting/mounting suspension component parts, disassembling/assembling suspension
parts and inspecting/replacing suspension component parts.
It consists of two (2) Learning Outcomes that contains learning activities for both
knowledge and skills supported with information sheet, job/operation sheet and self-check.
Before attempting to perform the manual exercises, see to it that you have already read and
understood the information/operating sheet and answer correctly the self-check provided in
every Learning Activities.
Upon completion of this module, you have to undergo the assessment to be administered
by your instructor. A certificate of completion (COC) will be given to you as a proof that you met
the standard requirements for this module. The assessment could be made in different methods
as prescribed in the competency standards.
Learning Outcomes :
Assessment Criteria :
Prerequisite : Before you tackle this module you must complete first the module in Overhauling
Brake System.
Assessment Criteria :
Resources :
1. Simulated workplace
2. Suspension mock-up
3. CD, Tapes, Transparencies, Books
• After learning activity 1, proceed to the next activity • After finishing this learning
• You can now identify suspension failure knowing all activity, answer the self
these causes? checks.
• The next activity will help you identify suspension • Have your instructor check
failure. your work before going any
further.
2. Identifying suspension system failure
a. Suspension System Diagnosis Chart • Perform Job Sheet LO1-7
b. Road Test Vehicle
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• Read Info. Sheet no. LO2-1
3. Lifting a vehicle • Read Job Sheet no. LO2-9
a. Hydraulic Jacks
4. Observing vehicle, workshop area, and equipment • Read Info. Sheet no. LO2-2
safety procedure.
a. Shop Safety Rules
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INFORMATION SHEET LO1-1
Purpose of Suspension System
The front suspension of a vehicle is designed so the steering knuckle and spindle can
pivot on the steering axis to allow steering of the vehicle. The spindle must also rise and fall,
relative to the body, to allow the springs and shock absorbers to reduce bump and road shock
from the vehicle’s ride. The suspension system allows the springs and shock absorbers to
absorb the energy of the bump, so passengers can have a smooth ride. While doing these two
jobs, the suspension system must not allow loose, uncontrolled movement of the tire and wheel
and must keep the alignment of the tire as correct as possible.
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SELF CHECK LO1-1a
IDENTIFICATION
A.
B.
C.
D.
E.
A.
B.
C.
D.
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C. Identify the parts of this suspension.
A.
B.
C.
D.
E.
A.
B
C.
D.
E.
F.
A.
B.
C.
D.
E.
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ANSWER KEY LO1-1a
(SUSPENSION)
A. IDENTIFICATION
B. Ball joints
A. Follower
B. Tension load carrying
C. Compression load carrying
D. Follower
C. Strut suspension
A. Damper/upper mount
B. Spring
C. Strut/shock absorber
D. Steering knuckle
E. Lower control arm
D. Strut suspension
A. Upper mount
B. Bearing
C. Insulator
D. Spring
E. Strut
F. Jounce bumper
E. Swing Axle
A. Pivot bushing
B. Axle
C. Steering knuckle
D. Radius arm
E. Spring
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SELF CHECK LO1-1b
1. Identify the parts of this rear suspension
A.
B.
C.
D.
E.
F.
G.
H.
A.
B.
C.
D.
E.
A.
B.
C.
D.
E.
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4. Identify the parts of this leaf spring assembly
A.
B.
C.
D.
E.
F.
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ANSWER KEY LO1-1b
1. Solid axle
a. axle
b. control arm
c. driveshaft
d. torque arm
e. stabilizer bar
f. shock absorber
g. Panhard rod
h. Spring
2. Solid axle
a. pivot bushing
b. cross beam
c. spring and insulator
d. shock absorber
e. trailing arm
3. Strut
a. Spring
b. Stabilizer bar
c. Shock absorber
d. Knuckle
d. Control arm
a. bushing
b. center bolt
c. shackle
d. bushing
e. main leaf
f. spring clip/U-bolt
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SELF CHECK LO1-1c
TRUE OR FALSE (Front Suspensions)
1. In an S-L A suspension, the short upper arm is parallel to the longer, lower arm.
2. The upper and lower ball joints are the steering axis in an S-LA suspension
3. The roll center is at the center of the car on a line between the center of the tire’s
road contact and the instant center.
4. Placing the upper and lower control arms at angles (viewed from the side) creates a
resistance to brake drive
5. On most S-L A cars the load carrying ball joint is on the lower control arm
Multiple Choice
3. The spring is on the lower control arm, and the steering knuckle is arranged so the outer
end of the control arm is between the ball joint bosses of the steering knuckle. This
control arm will use ball joint
a. compression loaded, load carrying c. follower
b. tension loaded, load carrying d. none of these
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ANSWER KEY LO1-1c
TRUE OR FALSE
1. FALSE
2. TRUE
3. TRUE
4. TRUE
5. TRUE
MULTIPLE CHOICE
1. A
2. D
3. A
4. C
5. D
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SELF CHECK LO1-1d
TRUE OR FALSE (Rear Suspensions)
1. During acceleration, excessive rear axle windup can cause wheel hop.
2. A Panhard rod and a track bar do the same.
3. A semi-trailing arm suspension allows vertical tire motion with zero camber change
4. With IRS, wheel hop during acceleration is prevented by the control arms.
5. A torque arm is used on some coil sprung rear axles to prevent axle windup and wheel
hop
MULTIPLE CHOICE
1. In many year suspensions (a) a Panhard rod is used to control the sideways position of
the rear tires, (b) a stabilizer bar is used to reduce vehicle lean on turns. Which is
correct?
a. A only c. both A and B
b. B only d. neither A nor B
2. In coil spring, solid axle suspension (a) the fore-aft position of the axle is controlled by
track rods, (b) upper and lower control arms are used to control windup. Which is
correct?
a. A only c. both A and B
b. B only d. neither A nor B
3. In a leaf spring rear suspension, the spring can be used to locate the (a) fore-aft
position of the wheels, (b) sideways position of the axle. Which is correct?
a. A only c. both A and B
b. B only d. neither A nor B
4. In rear suspensions, (a) the lower control arms are used to locate the fore-aft position of
the tires (b) a rigid axle housing can maintain correct rear wheel alignment. Which is
correct?
a. A only c. both A and B
b. B only d. neither A nor B
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ANSWER KEY LO1-1d
TRUE OR FALSE
1. TRUE
2. TRUE
3. FALSE
4. FALSE
5. TRUE
MULTIPLE CHOICE
1. C
2. B
3. C
4. C
5. B
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INFORMATION SHEET LO1-2
Types of Front Suspension
There are essentially five types of front suspensions used on cars, pickup, and trucks:
Short Long Arm (SLA), multilinks, MacPherson strut, swing axle, and solid axle.
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Newer multilink, long-knuckle SLA designs
use a strut-mounted spring (Figure LO1-2c).
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Most cars position the control arm under
the steering knuckle mount, so the load tries to
pull the ball joint apart. These are called
tension-loaded ball joints (Figure LO1-2e).
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Some vehicles use a type of ball joint and
tie rod end called low friction. These joints use
a very smooth ball and a socket that is lined
with a very slick polymer plastic material.
These joints are normally permanently
lubricated, use an improved grease seal, and
have no grease fitting. Low friction joints are
most common on lighter vehicles.
Multilink Suspensions
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Modified Struts
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Solid Axle
As mentioned earlier, solid axles are not
used on passenger cars because of their
harsher ride and inferior handling
characteristics on uneven roads. They are
commonly used on trucks, 4WDs, and
some pickups because of their minimum
number of wear points. A solid axle is
simply a strong, solid beam of steel
(usually I shaped) with a kingpin at each
end to connect to the steering knuckle.
This axle is called a monobeam by one
manufacturer (Fig. LO1-2n).
Figure LO1-2n. A solid axle with springs and
steering linkage.
Swing Axles, Twin I-Beam Axles
Other front suspension types have been Figure LO1-2o. A twin I-beam front suspension.
used on cars, but these are not in current This particular swing axle design uses two ball
joints to connect the steering knuckle to the axle.
use or commonly used by any major
manufacturer. The last one of these used
to a large extent was the trailing arm
suspension. The steering knuckle support
is attached to one or pair of trailing arms.
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SELF CHECK LO1-2a
A.
B.
C.
D.
E.
F.
G.
H.
I.
A.
B.
C.
D.
E.
F.
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ANSWER KEY LO1-2a
1. Single tube
a. pressure tube
b. oil chamber
c. gas pressure chamber
d. piston rod\
e. working piston and valve
f. dividing piston
2. Double-tube
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SELF CHECK LO1-2b
MULTIPLE CHOICE
2. With an air spring, (a) car height for a parked vehicle is maintained by the rubber
membrane, (b) The spring rate rises during jounce. Who is correct?
a. A only c. both A and B
b. B only d. neither A nor B
3. With col springs, (a) coil clash is a sign of a sagged spring (b) a nick in the paint can
cause spring breakage. Which is correct?
a. A only c. both A and B
b. B only d. neither A nor B
4. With torsion bars, (a) a problem with low ride height can be corrected by adjusting them
(b) the main way to change the load rate is adjusting the length of the lever arm. Which is
correct?
a. A only c. both A and B
b. B only d. neither A nor B
5. Stabilizer bars
a. reduce body lean on turns c. add roll resistance to the suspension
b. will make a one wheel bump harsher d. all of these
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ANSWER KEY LO1-2b
TRUE OR FALSE
1. FALSE
2. TRUE
3. FALSE
4. TRUE
5. TRUE
MULTIPLE CHOICE
1. B
2. B
3. C
4. A
5. D
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SELF CHECK LO1-2c
2. Air in the working chamber of a shock will cause (a) overheating, (b) mushy operation.
Which is correct?
a. A only c. both A and B
b. B only d. neither A nor B
3. In a single-tube shock absorber, the (a) extension valves are in the working piston, (b)
compression valves are in the base valve. Which is correct?
a. A only c. both A and B
b. B only d. neither A nor B
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ANSWER KEY LO1-2c
MULTIPLE CHOICE
1. B
2. B
3. A
4. D
5. D
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INFORMATION SHEET LO1-3
REAR SUSPENSION TYPES
Rear suspensions are very similar to front suspensions in that they allow vertical tire
movement. However, in most cases, they do not allow steering, and in cases in which four-
wheel steering is used, the steering is very limited.
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Solid Axle, Coil Spring Suspension
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IRS, Semitrailing Arm Suspension
In the IRS, semitrailing arm suspension design, each rear tire and wheel is mounted on a
single control arm, which is usually mounted to the frame through one or a pair of rubber
bushings (Fig. LO1-3g).
Figure LO1-3g. Semitrailing arms support the rear wheel bearings to control camber and toe angles, as
well as control the wheelbase. Note the angles of the front pivot bushings that make these semitrailing
arms.
Figure LO1-3h. In early Corvettes, (A) a single trailing am controlled wheelbase, brake torque, and toe
angle; camber angle was controlled by the axle shaft and lower strut. In newer Corvettes, (B) a five link
suspension uses two trailing arms to control wheelbase and braking torque, a tie rod to control toe
angle, and a spindle support rod and axle shaft to control camber angle.
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IRS Strut Suspension
Strut suspension in an IRS closely resembles the strut suspension used on front wheels
RWD strut suspensions are called Chapsman struts (Fig. LO1-3i).
Figure LO1-3i. This strut suspension uses two lower suspension arms to control track and toe angle; the
strut rod controls wheelbase.
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Figure LO1-3k. This wheel drive van uses a de
Dion style axle. The driveline module containing
the differential is attached to the vehicle
underbody.
FWD Rear Axles
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FWD, Rear Trailing Arm Suspension
Nonpowered rear struts normally used a strut, control arm, and strut rod to control rear tire
and wheel movement. The spring can be mounted on the strut or between the car body and the
lower control arm to save mounting room. In some designs, the lower control arm is replaced
by a pair of lateral links (Fig. LO1-3n.).
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Figure LO1-3n. Several styles of rear strut
suspensions for RWD cars. Note the type and
location of the spring and the different styles of
lower control arms.
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SELF-CHECK LO1-3
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ANSWER KEY LO1-3
a. Solid Axle Leaf Spring Suspension – is the simplest form of rear suspension. A pair
of leaf springs attaches to the frame through rubber bushings at the front and through
rubber bushings and a shackle at the rear. The rear axle housing bolts solidly to the
center of the spring with a set of U-bolts. The front portion of the springs acts as a
control arm, positioning the rear axle housing and establishing the wheelbase.
b. This rear suspension has a single upper control arm to prevent axle rotation. Side motion
is controlled by the track bar, also called Panhard rod; the track bar connects to the axle
at the left end.
c. Semitrailing arms support the rear wheel bearings to control camber and toe angles, as
well as control the wheelbase. The angles of the front pivot bushings that make these
semitrailing arms.
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INFORMATION SHEET LO1-4
TYPES OF SPRINGS
Types of Springs
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INFORMATION SHEET LO1-5
SHOCK ABSORBERS
The purpose of the hydraulic shock Figure LO1-5b. shows the shock absorber action in
absorber is to dampen spring oscillations. It a variable damping strut. During normal driving,
does not support the weight of the vehicle, nor grooves in the strut tube allow fluid to pass around
does it affect vehicle height. the piston. When the wheel suddenly drops into a
pothole in the road, the tube extends more than
normal. Now the piston is above the grooves. The
Shock Absorber Operation fluid can pass only through the holes in the piston.
This increases the resistance to piston movement
It is basically an oil-filled cylinder or tube in and reduces the impact of the suspension against
which a piston moves up and down (Fig. 1). its stops.
This forces the oil or hydraulic fluid in the
cylinder to flow through small fluid passages or
orifices in the piston. The resulting fluid friction
limits spring bounce.
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Figure LO1-5c. Shock absorber action in a variable
damping strut.
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Many vehicles have automatic level control
or electronic level control (Fig. LO1-5d). The
two rear air shock absorbers are connected by
air lines to an air compressor on the vehicle.
At least one of the shock absorbers includes a
height sensor. It signals the electronic control
module (ECM) when the load in the rear of the
vehicle has caused a change in vehicle height.
The ECM then switches on the air compressor
to add air to the shock absorber. Removing
the load causes the ECM to open the air valve.
This bleeds air from the system.
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INFORMATION SHEET LO1-6
SPRING OPERATING PRINCIPLE
The springs make the load carrying connection between the suspension members and the
frame. Springs have the ability to bend or twist and absorb energy when they are compressed
to shorter lengths. When a tire meets an obstruction, it is force upward, and the energy of this
upward motion is absorbed by the spring rather than transmitted to the frame and body of the
vehicle. The spring however only absorbs this energy for a brief period; as soon as possible, it
releases the energy by extending back to its original length. This extension either pushes the
tire back down on the road or lifts the car if he obstacle is still under the tire.
When the spring releases its stored energy, it does so with such quickness and
momentum that the end of the spring usually extends too far. The spring goes through a
series of oscillations, contractions, and extensions until all of the energy in the spring is used up
or released. The speed of these oscillations depends on the natural frequency of the spring and
suspension. A car with undampened springs (i.e., no springs) tends to bounce up and down in
time to these oscillations. In most cases, this bounce frequency is disturbing to the driver or
passengers. A stronger spring oscillates at a faster frequency than a softer one. Many
manufacturers purposely mismatch the spring frequency at the front and at the rear to obtain a
flatter, more acceptable ride.
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INFORMATION SHEET LO1-7
SHOCK ABSORBER OPERATING PRINCIPLE
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INFORMATION SHEET LO1-8
DIAGNOSIS CHART
C P
Vi o WC C
br h Ti h C
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W h
h C
Br h
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D h
ri In
D h
a
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Ex n R h C
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Im Ina C h
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Pu U C
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or n C h
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Br h C
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In C o
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In h
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P h
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Bi h
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pr M e Ch
is h
Figure LO1-8a. Steering and Suspension System Diagnosis Chart
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TROUBLE TREE
Figure LO1-8b. This is a procedure to locate the cause of a lead or pull condition. We
begin at the top and work our way until the cause is located and remedied.
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SELF CHECK LO1-8a
1. Describe briefly how the car should be lifted to check each of these ball joint.
A.
B.
C.
D.
E.
F.
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4. What is this technician doing?
What is it?
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ANSWER KEY LO1-8a
1. A, B, and F: Lift by frame with prop under upper arm, C, D, and E: Lift under lower
control arm.
2. He is checking a wear indicator ball joint. If he can’t rotate the perk fitting, the ball joint is
worn.
3. If this dimension changes more than 3/32” when the ball joint is unladed, the ball joint is bad.
4. He is checking for play at the wheel bearings, ball joints, king pin, and control arm bushings
5. Measure the distance it moves as the vehicle is lifted or measure the amount of side
motion as the spring is pushed and pulled
6. He is checking for play in the steering linkage, wheel bearings, tie rod ends, idler
arm, Pitman arm end, steering gear, steering couplers.
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INFORMATION SHEET LO1-9
Figure LO1-9a. Hydraulic floor jack and Fig. LO1-9c. Jack stands are used under to support the
engine support tool vehicle.
Figure LO1-9b. Designated lift points for one vehicle, specified by the vehicle manufacturer
The automotive shops use a variety of hydraulic jacks. One type is the portable floor jack
(Fig.LO1-9a.). Pumping the handle increases the pressure in the hydraulic cylinder. This causes
the ram to extend and raise the lifting saddle. Turning the top of the handle or moving a lever on
the handle releases the pressure. Then the saddle and load settle back down.
Always lift at the proper lift point under the vehicle (Fig. LO1-9b). If in doubt,
refer to the vehicle manufacturer’s service manual. Lifting at the wrong points can
cause vehicle damage.
CAUTION!
Never work under a vehicle supported only by a jack. Always support the vehicle on safety
stands before going under it (Fig. LO1-9c) A jack could slip or release. Then the vehicle would
fall on you. Serious injury or death could result.
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INFORMATION SHEET LO1-10
SHOP SAFETY RULES
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Fig. LO1-10b. Always wear safety glasses, safety Figure LO1-10c. Always wear eye protection when
goggles, or a face shield when liquid spray or using a grinding wheel.
particles are flying or falling around you.
15. Keep your hands away from the engine fan and accessory drive belts when the engine is
running. Your hand could get caught in the fan r between a belt and a pulley. You could
be badly cut or even lose a fingers.
16. Do not stand directly in line with the engine fan when it is turning or the engine is running.
Some fans, especially fans with flexible blades, have thrown off a blade while spinning. A
flying fan blade may injure or kill anyone it strikes.
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JOB SHEET LO1-1
INSPECT SUSPENSION SYSTEM
The purpose of an inspection is to
determine the cause for the vehicle owner’s
complaint and to determine what steps will be
needed to cure the complaint. It is a god
practice to note any other parts that show
signs of failing in he near future so the
customer ca be aware of them. The
suspension should operate for many miles and
a year or so until the next time it is inspected;
the average motorist does not check
suspension components very frequently
(Figure LO1.1a).
Figure LO1-1a. As the suspension parts wear, they
allow the alignment of the front tires to chance and
permit uncontrolled, sloppy tire movement.
SAFETY TIP: A suspension, steering, or brake failure can place the car and its passengers in a
highly dangerous situation. While making an inspection, this fact is in the forefront of the front-
technician’s mind. Any item that might fail in the near future and cause an accident is noted
and brought to the car owner’s attention.
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10. Control arm bushings and end links for wear or deterioration.
11. Strut rod bushings for wear deterioration.
12. Stabilizer bar bushings and end links for wear or deterioration.
13. Springs for loose or broken parts.
14. Shock absorbers or strut for leakage, loose or broken mounts or broken parts.
15. Tie rods for looseness or torn boots.
Many technicians follow an inspection checklist (Fig LO1-1b). The checklist helps ensure
that none of the checks is missed or forgotten, and it allows a more professional discussion with
the car owner.
An inspection of the springs and the shock absorbers often begins with a customer
complaint of noise, tire wear low vehicle (one end, one side or all over, excessive vehicle
leaning on turns, or front end dive under braking. Any of these complaints might indicate
weak or broken springs or shock absorbers.
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Figure LO1-1b. Many technicians follow a checklist like this to ensure that they do not skip any checks and also
to give the car owner a record of what was found during the inspection.
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ASSESSMENT TASK LO1-1
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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OPERATION SHEET LO1-1
PURPOSE :
The bounce test is a simple and quick test that should give an indication of the
condition of the suspension system.
PROCEDURE:
1. Grip one end of the bumper and alternately
pull upward and push downward several
times until you get that corner of the car
bouncing up and down as high as you can.
While the car is bouncing up and down,
listen for any unusual noises that might
indicate worn or broken parts.
2. With the car at the upper end of a bounce,
release the bumper and watch the
remaining oscillations until they stop. Two
or more oscillations indicate the possibility
of worn shock absorbers or, less likely
worn front-end bushings (Fig 1).
3. Repeat steps 1 & 2 at the other end of the
bumper and compare the bouncing action
of the two sides of the car. They should be Figure 1. A shock absorber bounce test is manually
the same; a difference indicates a weak performed by bouncing each corner of the car; with the
car bouncing as much as possible, it is released and the
shock absorber or worn suspension bouncing action is observed. If it bounces more than
bushings. one and half oscillations, the shock absorber is probably
weak.
4. Repeat steps 1, 2 and 3 at the other end of the car. Do not compare the number of bounces
of the front with the rear; they are often different.
A car with no more than one or two bounce oscillations after releasing the bumper at
each corner of the car and with smooth, quite operation probably has good springs and shock
absorbers, if the height and ride quality are good. Unusual or excessive noises, differing
number of bounce oscillations at each side of the car, or excessive bouncing indicates a need
to follow up the bounce test with one of the remaining tests.
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ASSESSMENT TASK LO1-2
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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No. e ne rch 8
OPERATION SHEET LO1-2
PURPOSE :
A suspension ride height check is a simple and quick way to determine if the car is
too low; weak, sagging springs let the suspension height drop.
PROCEDURE:
1. Park the car on a smooth level surface; the ramps of a wheel alignment rack are ideal
because they are level and allow easy access to the suspension members.
2. Check for unusual amounts of weight that might be in the trunk or backseat of the car. Hey
should be removed or allowances made for any added weight; ride height specifications are
given for unloaded cars.
3. Check the tire pressure and correct it, if necessary. Note whether the tires are stock size; if
not, allowances must be made in the checking dimensions.
4. Obtain the ride height specifications and the locations of the measuring points.
5. Measure the distances at each measuring point and compare them with the specifications.
Sagged springs are indicated if the measured distances are shorter or lower than the
specifications.
6. Compare the left and right measurements; they should be almost equal.
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Figure 3. Ride height measurements are made at different locations as determined by the vehicle manufacturer.
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ASSESSMENT TASK LO1-3
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
Y N
PE
E O
CRIT
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-2
CHECK BALL JOINTS
Ball joint boots are checked visually (Fig. 4); the area behind the boot and ball joint where
you cannot see can be checked by running your finger around the boot and feeling for
problems Look or feel for grease outside of the boot, which indicates breaks or tears. If the boot
is torn,
the ball joint will probably fail, if it has not already, and should be replaced (Fig. 5). While
checking the boot, squeeze it to ensure that there is grease inside of the boot. An empty boot
indicates a need for lubrication.
Lubrication requirements for a ball joint vary among manufacturers. The lubrication
intervals for modern joints are rather long; one manufacturer, for example, requires
lubrication every 3 years or 30,000 miles (48000 Km). Long interval such as this makes it
easy for the average motorist to forget about lubricating ball joints completely. Low friction
ball joints are permanently sealed and require no further lubrication.
Figure 5. A cut or torn ball joint boot will let the grease
escape and allow dirt and water to enter the joint; if the
joint is not already worn out, it will soon fail
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4. On some styles, grip the grease fitting
with your fingers and try to rotate it; if the
grease fitting can be rotated, the ball
joint is excessively loose and should be
replaced (Fig. 6).
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ASSESSMENT TASK LO1-4
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-3
CHECK KINGPIN CLEARANCE
Although kingpins are not ball joints, they have been included with these checks because
a kingpin performs a similar function and the checking method is similar. Kingpins are used on
solid axles and some twin I-beam axles; they are normally checked by measuring the side
shake of the tire.
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ASSESSMENT TASK LO1-5
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-4
4. Swing the tire rapidly back and forth while forcing it to bump at the steering stops; also,
force the tire in and out. While doing this, watch the control arm for any motions that
would indicate bushing failure.
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5. On single lower control arms, try prying the inner end of the control arm sideways using a
pry bar or large screwdriver. A slight motion is acceptable; larger motions indicate weak
bushings.
1. Bounce the suspension while listening for squeaks or other bushing related abnormal
noises. If possible, place our finger lightly on the bushing while bouncing the front end; a
noisy bushing will often have a rough, harsh feel. Noisy bushings can sometimes be
cured by greasing them, but if they have squeaked for very long, they are probably worn
and should be replaced.
3. Swing the tire back and forth rapidly, so the turning stops strikes rather hard, and watch
the control arm bushings. A very slight amount of side motion is acceptable, but a
definite motion or jumping of the control arm on the shaft indicates a faulty bushing.
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ASSESSMENT TASK LO1-6
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-5
CHECK STRUT ROD BUSHINGS
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No. e ne rch 0
ASSESSMENT TASK LO1-7
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-6
Occasionally, the tire on a strut suspension
shows excessive camber wear, which indicate
that the strut body or strut piston rod might be
bent. Several checks can be made to
determine if this has occurred.
To check for a bent piston rod, loosen the piston rod at the upper mount and then rotate the
piston rod while you watch for side motion at the top of the tire or strut body. A good strut rod
should rotate evenly with no side motion of the tire or strut body.
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No. e ne rch 2
ASSESSMENT TASK LO1-8
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
e
l
e
c
t
e
d
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JOB SHEET LO1-7
ROAD TEST
A technician road tests the vehicle to confirm the nature of the problem and also to try to
determine the cause. Most technicians have a preferred test route that provides various
bumps and road surfaces and is away from heavy traffic. During a road test, the vehicle is
driven in a manner to try to simulate the particular problem. In other words, if you are checking
for a noisy shock, you want a rough road; if you are checking a pull condition or vibration
problem, you want a smooth road. Finding a good test route that is close to the shop can be
difficult in many metropolitan arrears.
While conducting a road test, you should observe the following guidelines:
Make sure the vehicle is safe to operate by quickly checking the tires, brake pedal
operation, and steering wheel feel.
Observe all pertinent traffic laws.
Use the vehicle’s seat and shoulder belt.
Drive the vehicle in a normal manner so you will not cause any additional wear or
damage.
Note the operation of the ABS and airbag warning lights if the vehicle is so equipped.
During the test, the technician will try to accomplish the following:
Note any unusual or unsafe condition to be brought to the attention of the owner.
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ASSESSMENT TASK LO1-9
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
P
e
r
o
r
m
e
d
p
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No. e ne rch 5
Qualification : Automotive Servicing NC III
Assessment Criteria:
Resources:
PREFERENCES:
Before performing the activities, be sure that you are skilled in the following:
• Observing safety practices in the workshop;
• Using jacks, lifts and hoists to lift the vehicle
• Maintaining auto mechanic’s tools and equipment.
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Lear
ning
LEASPE
• G CI
1
.
R
e
m
o
v
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JOB SHEET LO2-1
Figure 1.
a. Raise the vehicle.
• Place safety stands under
the frame.
• Place the jack under the
lower control arm. Get it as
close to the lower ball joint
as possible.
b. Remove the tire and wheel
assembly.
c. Remove the rebound bumper
from the upper control arm
(Figure 2). Do this by removing Figure 2.
the hold-down bolt.
Figure 3.
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f. Break the ball joint loose
between the tapered ball stud
and the tapered hole in the
steering knuckle. Use method
number 1 (Figure 4).
Figure 4.
• Use one wrench to hold the
adjusting bolt on the tool.
Use a second wrench to
turn the tool for tightening
and loosening (Figure 5).
Note: If only the ball joints are to be replaced, stop at this point.
2. Remove a lower control arm assembly on a lower control arm mounted spring.
Figure 9..
b. Remove the tire, wheel and drum
assembly.
Figure 10.
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d. Disconnect the stabilizer at the control arm
(Figure 11).
Figure 11.
e. Disconnect the strut rod from the control
arm, if so equipped.
Figure 12.
h. Raise the lower control outer end enough to
take the pressure off the lower ball joint
(Figure 12).
Figure13.
j. Loosen the lower stud nut approximately
two turns.
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• Adjust the bolt on the tool to fit snugly
against the lower ball stud.
• Tighten the tool with one wrench while
holding the adjusting bolt with another
wrench (Figure 15).
• Tighten the tools until the studs are
under tension.
Figure 17.
q. Remove the control arm pivot bushing bolts
(Figure 18). Unscrew the nut and remove
the bolt on both pivot bushings.
Figure 18.
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SELF-CHECK LO2-1
Directions: At this time, check your skills by reviewing the following criteria.
1. Remove the upper control arm assembly on a lower control arm mounted coil spring.
2. Remove the lower control arm assembly on a lower control arm mounted coil spring.
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ASSESSMENT TASK LO2-1
Your trainer will provide you with the necessary tools and equipment for the job, and
supervise you in your work; you will be graded based on the list below:
PEY N
CRIT
E O
1
.
S
u
p
p
o
r
t
h
e
v
e
h
i
c
l
e
t
o
u
n
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No. e ne rch 4
PERFORMANCE TEST
L D
e at
C T
o
m
D O
i L VPE
e
r v R
e 4 - Can
perform this
c skill without
t 3-
i Ca
o n
n 2 - Can
perform
s this skill
: 1 - Can
perform
C parts of
A In
str
RY N N
e o /
1 s A
2.
3.
A
4. r
S
5. u
S
6. us
Damage
7
8. Test
conduct
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ASSESSMENT INSTRUMENT
EVIDENCE PLAN
C Au
o
ti
R
n a
i
Ways Su
in
whic
Question/Interview
h
Demonstration
Practical
Portfolio
Written
T
* e
Identif
Ty
pe
Pr
in
ci
P
* art
Caus
Sy
st
*
Dism
ountin
S
us
N
o
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S
af
C
r
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Da
ma A
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C
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Testin
PER
CENT
P D
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D
h at
e e:
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GLOSSARY
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Spring – A flexible suspension member that allows bounce travel of the suspension
Spring rate – The change of load on a spring per unit of deflection.
Sprung weight –The total weigh of the portions of the car that are carried by the
springs. Stabilizer bar –A suspension member used to reduce body lean during
cornering. Steering axis – The line around which the front tires turn when the car turns a
corner.
Steering Axis Inclination (SAI) – An angle of the steering axis in which the top of the steering
axis leans inward.
Steering knuckle –The front suspension component that attaches the front tires and wheels to
the steering axis and steering linkage.
Strut – A suspension system type hat utilizes the shock absorber as the upper tire position
locating member
Strut rod – A suspension member that is used to brace the control arm to keep it from moving
forward or backward.
Toe – An angle of the tire, relative to straight ahead, if viewed from above.
Toe angle - The actual amount that the tire differs from pointing ahead.
Torsilastic bushing – A bushing that allows motion through the elastic nature of rubber.
Torsion bar – A spring that allows suspension motion by twisting.
Watt’s link – A suspension member consisting of two rods and a pivoting bell crank that is used
to keep the body from moving sideways relative to the axle.
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Learner’s diary
DIARY NOTES
Record important dates, jobs undertaken and other workplace events that will assist you in providing further
details to an Assessor.
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Record of Achievement
LO 1 : Identify the types of suspension system, component and its operating principle
(Conventional and Air suspension).
Performance Criteria:
1.1 Types of suspension were identified, explained and differentiated.
1.2 Main component and functions of suspension system were identified.
Comments:
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Record of Achievement
Performance Criteria:
2.1 Causes of failure were accurately identified.
2.2 System failure was properly identified.
2.3 Vehicle was properly lifted and jack stands were used.
2.4 Vehicle, workshop area, and equipment safety procedure were observed.
Comments:
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ACKNOWLEDGEMENT
Copyright TESDA
Centex: SOUTHERN ISABELA COLLEGE OF ARTS AND TRADES
Technology Instructors:
1. Exsuperio G. Jacinto
2. Jeronimo L. de Jesus
3. Dante V. Balagot
4. Leopoldo P. Bueno
Academic Teachers:
1. Sonita Dr. Camacam
2. Llarena T. Ocampo
3. Elena C. Echija
4. Jovita P. Pasamic
Facilitator:
Cesar G. Ancheta
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No. e ne rch 2