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qxd 4/20/05 1:00 PM Page i

TechOne:
Automotive
Suspension
and Steering
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TechOne:
Automotive
Suspension
and Steering
Jack Erjavec
Professor Emeritus,
Columbus State Community College
Columbus, Ohio
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TechOne: Automotive Suspension and Steering

Jack Erjavec

Vice President, Technology Marketing Director: Production Editor:

and Trades SBU: Dave Garza Barbara L. Diaz
Alar Elken Channel Manager: Art/Design Specialist:
Editorial Director: William Lawrenson Cheri Plasse
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Acquisitions Editor: Mark Pierro Kevin Smith
David Boelio Production Director: Technology Project Specialist:
Developmental Editor: Mary Ellen Black Linda Verde
Matthew Thouin Editorial Assistant:
Andrea Domkowski

COPYRIGHT 2006 by Thomson Delmar ALL RIGHTS RESERVED. No part of this Library of Congress Cataloging-in-
Learning, a division of Thomson Learning, work covered by the copyright hereon Publication Data:
Inc.Thomson, the Star logo, and Delmar may be reproduced in any form or by any
Learning™ are trademarks used herein means—graphic, electronic, or Erjavec, Jack.
under license. mechanical, including photocopying, Tech one. Automotive steering and
recording, taping, Web distribution, or suspension / Jack Erjavec.
Printed in the United States of America information storage and retrieval p. cm.
1 2 3 4 5 XX 06 05 04 systems—without the written permission Includes index.
of the publisher. ISBN 0-7668-1166-2
For more information contact 1. Automobiles--Springs and suspension—
Delmar Learning For permission to use material from the Maintenance and repair. 2. Automobiles—
Executive Woods text or product, contact us by Steering-gear--Maintenance and repair.
5 Maxwell Drive, PO Box 8007, Tel. (800) 730-2214 I.Title.
Clifton Park, NY 12065-8007 Fax (800) 730-2215 TL257.E77 2005
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Web at www.delmarlearning.com 2005043950

ISBN: 0-7668-1166-2

NOTICE TO THE READER

Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any
of the product information contained herein. Publisher does not assume, and expressly disclaims, any obligation to obtain and include
information other than that provided to it by the manufacturer.

The reader is expressly warned to consider and adopt all safety precautions that might be indicated by the activities herein and to avoid all
potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions.

The publisher makes no representation or warranties of any kind, including but not limited to, the warranties of fitness for particular purpose
or merchantability, nor are any such representations implied with respect to the material set forth herein, and the publisher takes no
responsibility with respect to such material.The publisher shall not be liable for any special, consequential, or exemplary damages resulting, in
whole or part, from the readers’ use of, or reliance upon, this material.
11662 FM.qxd 4/20/05 1:00 PM Page v

Contents
Preface xi CHAPTER 3 • TOOLS OF THE TRADE 21
About the Author xiii Introduction 21
Acknowledgments xiv Hand Tools 21
Features of the Text xv Service Information and Manuals 22
Power Tools 23
Shop Tools 24
SECTION 1: SAFETY AND COMMUNICATION 1 Suspension and Steering Tools 26
Summary 32
Chapter 1 • SAFE WORK PRACTICES 3 Review Questions 32
Introduction 3
Safe Work Areas 3 CHAPTER 4 • WORKING AS A SUSPENSION
Personal Safety 3 AND STEERING SPECIALIST 33
Fire Hazards and Prevention 4 Introduction 33
Safe Tools and Equipment 5 Compensation 33
Batteries 7 Employer-Employee Relationships 34
Accidents 8 ASE Certification 35
Air Bag Safety and Service Warnings 8 Duties of a Suspension and
Hazardous Materials 9 Steering Specialist 36
Occupational Safety and Health Cleaning with Chemicals 37
Administration (OSHA) 10 Summary 39
Handling Shop Wastes 10 Review Questions 39
Summary 11
Review Questions 11
SECTION 2: BASIC THEORIES AND SERVICES 41
CHAPTER 2 • MEASURING SYSTEMS, FASTENERS,
AND MEASURING TOOLS 13 CHAPTER 5 • BASIC ELECTRICAL THEORY 43
Introduction 13 Introduction 43
Measuring Systems 13 Basic Electricity 43
Fasteners 15 Electrical Terms 44
Bbolt Identification 15 Electrical Circuits 44
Tightening Bolts 16 Conductors and Insulators 45
Measuring Tools 16 Ohm’s Law 45
Micrometers 19 Circuit Components 46
Summary 20 Electromagnetism Basics 47
Review Questions 20 Basics of Electronics 48

v
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vi • Contents
Summary 50 Detailed Inspection 105
Review Questions 51 Power Steering 108
Lubricate Suspension and Steering Systems 109
CHAPTER 6 • BASIC ELECTRICAL SERVICE 52 Summary 109
Introduction 52 Review Questions 110
Quick Overview of Electricity 52
Electrical Problems 53
Basic Electrical Testing 54 SECTION 3: TIRES AND WHEELS 111
Electrical Wiring Diagrams 57
Testing Circuit Protection Devices 57 CHAPTER 10 • WHEELS 113
Testing Switches 58 Introduction 113
Basic Electrical Repairs 58 Construction 113
Summary 59 Wheel Sizes 115
Review Questions 59 Wheel Offset 115
Replacement Wheels 115
CHAPTER 7 • SUSPENSION AND STEERING SYSTEMS 61 Wheel Attachment 116
Introduction 61 Servicing Wheels 117
Wheels and Tires 61 Wheel and Tire Installation 117
Suspension System Components 63 Summary 118
I-Beam Front Suspension Systems 66 Review Questions 118
Short-and-Long Arm (SLA) Front
Suspension Systems 66
CHAPTER 11 • TIRES 119
Introduction 119
MacPherson Strut Front Suspension
Tire Construction 119
System Design 67
Tire Ply and Belt Design 122
Performance Front Suspension Systems 68
Tire Ratings and Designations 124
Torsion Bar Suspensions 69
Specialty Tires 126
Steering Systems 69
Tire Placard and Inflation Pressure 129
Steering Linkage 70
Replacement Tires 129
Manual Steering Gears 72
Summary 130
Steering Wheels and Columns 74
Review Questions 130
Power Steering 75
Summary 78 CHAPTER 12 • DIAGNOSIS OF TIRE PROBLEMS 131
Review Questions 79 Introduction 131
Tire Wear Patterns 131
CHAPTER 8 • BASIC THEORIES 80 Tire Noises and Steering Problems 133
Introduction 80 Tire Thump and Vibrations 134
Matter 80 Steering Pull 134
Energy 81 Tire and Wheel Runout 134
Volume 82 Summary 137
Force 83 Review Questions 137
Motion 85
Work 86 CHAPTER 13 • TIRE AND WHEEL SERVICE 138
Waves and Oscillations 89 Introduction 138
Liquids 90 Wheel and Tire Removal 138
Gases 91 Tire Rotation 139
Heat 93 Tire and Wheel Service Precautions 139
Chemical Properties 94 Tire Demounting 140
Summary 97 Tire Repair 141
Review Questions 98 Wheel Rim Service 143
Tire Remounting Procedure 143
CHAPTER 9 • GENERAL SUSPENSION AND Installation of Tire/Wheel Assembly
STEERING SYSTEM DIAGNOSIS 99 on the Vehicle 144
Introduction 99 Tire Care 145
Road Test 99 Summary 145
Basic Inspection 103 Review Questions 145
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Contents • vii
CHAPTER 14 • BALANCING TIRE AND Summary 187
WHEEL ASSEMBLIES 146 Review Questions 187
Introduction 146
Tire Motion Forces 146 CHAPTER 19 • SERVICING NON-DRIVE
Static Wheel Balance Theory 146 AXLE BEARINGS 188
Dynamic Wheel Balance Theory 147 Introduction 188
Preliminary Wheel Balancing Checks 149 Bearing Removal 188
Static Wheel Balance Procedure 149 Cleaning and Inspection 189
Dynamic Wheel Balance Procedure 151 Bearing Lubrication 191
Summary 153 Bearing Replacement 192
Review Questions 154 Bearing Adjustment 193
Summary 194
Review Questions 194
SECTION 4: WHEEL AND AXLE BEARINGS 155
CHAPTER 20 • SERVICING DRIVE AXLE BEARINGS 195
CHAPTER 15 • WHEEL BEARINGS 157 Introduction 195
Introduction 157 Servicing FWD Axle Bearings 195
Common Bearings 157 Replacing Front Axle Bearings 196
Front-Wheel Drive (FWD) Drive Axles 160 Servicing RWD Axles 199
Rear-Wheel Drive (RWD) Drive Axles 160 Removing Axles 199
Axle Bearing Designs 161 Axle Bearings 201
Wheel Bearings 162 Axle Shaft Seals 201
Seals 163 Installing Axles 202
Bearing Lubrication 164 Summary 202
Summary 165 Review Questions 202
Review Questions 165

CHAPTER 16 • DIAGNOSIS OF BEARING PROBLEMS 166 SECTION 5: SPRINGS, SHOCKS, AND STRUTS 205
Introduction 166
Basic Wheel and Axle Bearing Troubleshooting 166 CHAPTER 21 • SPRINGS 207
Tapered Roller Bearing Troubleshooting 167 Introduction 207
Wheel Hub Diagnosis 168 Spring Terminology 207
Summary 171 Coil Springs 208
Review Questions 171 Leaf Springs 209
Torsion Bars 211
CHAPTER 17 • FRONT-WHEEL-DRIVE (FWD) Stabilizer Bars 212
DRIVE AXLES 172 Summary 213
Introduction 172 Review Questions 213
Front Wheel Drive Axles 172
Drive Axle Supports 174 CHAPTER 22 • SHOCKS AND STRUTS 214
Types of CV Joints 174 Introduction 214
CV Joint Boots 177 Shock Absorber Design 214
Summary 178 Shock Absorber Operation 216
Review Questions 178 Strut Design 217
Electronically Controlled Shock
CHAPTER 18 • DIAGNOSING AND SERVICING Absorbers and Struts 219
FWD DRIVE AXLES 179 Summary 220
Introduction 179 Review Questions 221
Talk to the Customer 179
Road Test 179 CHAPTER 23 • SHOCK AND STRUT DIAGNOSIS 222
Visual Inspection 181 Introduction 222
CV Joint Wear 182 Diagnosing Front Suspensions 222
Servicing FWD Drive Axles 182 Air Shock Absorber Diagnosis 223
Drive Axle Removal 183 Electronic Air Suspension System Diagnosis 224
Bench Inspection 184 Shock Absorber or Strut Bounce Test 225
General Service Procedures 185 Shock Absorber Visual Inspection 225
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viii • Contents
Shock Absorber Manual Test 227 Coil-Spring Rear Suspension 266
Summary 227 Semi-Independent Rear Suspension Systems 268
Review Questions 227 Independent Rear Suspensions 268
Summary 272
CHAPTER 24 • SPRING SERVICE 228 Review Questions 273
Introduction 228
Effects of Weak Springs 228 CHAPTER 29 • COMPUTER-CONTROLLED
Selecting Replacement Springs 229 SUSPENSION SYSTEMS 274
Coil Springs 229 Introduction 274
Torsion Bars 231 Air Systems 274
Leaf Springs 232 Electronically Controlled Shock
Stabilizer Bars 234 Absorbers and Struts 280
Summary 234 Summary 283
Review Questions 235 Review Questions 284

CHAPTER 25 • SHOCK AND STRUT SERVICE 236 CHAPTER 30 • FRONT SUSPENSION DIAGNOSIS 285
Introduction 236 Introduction 285
On-Car Installation of a Strut Cartridge 236 Road Test 285
Front Strut Removal 237 General Front-Suspension Inspection 286
Strut Cartridge Replacement 240 Detailed Inspection 287
Strut Reassembly 241 Ball Joints 288
Strut Assembly Installation 241 Summary 290
Strut Disposal Procedure 242 Review Questions 291
Rear Strut Replacement 242
Shock Absorber Replacement 243
Summary 244
CHAPTER 31 • FRONT SUSPENSION SERVICE 292
Introduction 292
Review Questions 245
Steering Knuckles 292
Ball Joints 293
Control Arms 296
Control Arm Bushings 298
SECTION 6: SUSPENSION SYSTEMS 247 Strut Rods 299
Summary 299
CHAPTER 26 • FRAMES 249 Review Questions 300
Introduction 249
Frame Construction 249
Vehicle Directional Stability 251 CHAPTER 32 • REAR SUSPENSION DIAGNOSIS 301
Frame Checks 252 Introduction 301
Frame Straightening 253 Diagnosis 301
Summary 253 Lower Control Arm and Ball Joint Diagnosis 303
Review Questions 254 Track Bar Diagnosis 303
Tie Rod Inspection 304
CHAPTER 27 • FRONT SUSPENSIONS 255 Summary 304
Introduction 255 Review Questions 305
Basic Operation 255
Ball Joints 256 CHAPTER 33 • REAR SUSPENSION SERVICE 306
Short/Long Arm Front Suspension Systems 258 Introduction 306
MacPherson Strut Front Suspension Systems 260 Lower Control Arm and Ball Joints 306
Performance-Oriented Suspensions 261 Track Bar Replacement 309
Other Front Suspension Designs 263 Tie Rod Replacement 309
Summary 264 Summary 309
Review Questions 264 Review Questions 309

CHAPTER 28 • REAR SUSPENSIONS 265 CHAPTER 34 • ELECTRONIC SUSPENSION SERVICE 310

Introduction 265 Introduction 310
Leaf-Spring Rear Suspension 266 Preliminary Inspection 310
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Contents • ix
Air Systems 311 Adjustments 361
Electronically Controlled Shock Absorbers Summary 363
and Struts 316 Review Questions 363
Summary 319
Review Questions 319 CHAPTER 41 • RACK-AND-PINION STEERING SERVICE 365
Introduction 365
Steering Gear Removal and Replacement 366
SECTION 7: STEERING SYSTEMS 321 Manual Rack-and-Pinion Steering
Gear Disassembly 367
CHAPTER 35 • STEERING COLUMNS AND LINKAGES 323 Manual Rack and Pinion Steering
Introduction 323 Gear Assembly 369
Steering Wheels and Columns 323 Summary 370
Steering Linkages 326 Review Questions 370
Summary 330
Review Questions 330
CHAPTER 42 • FOUR-WHEEL STEERING SYSTEMS 371
Introduction 371
CHAPTER 36 • MANUAL STEERING GEARS 331
Four-Wheel Steering Theory 371
Introduction 331
Mechanical 4WS 372
Recirculating Ball Steering 332
Hydraulic 4WS 373
Worm and Roller Gears 334
Electro/Hydraulic 4WS 373
Rack-and-Pinion Steering Gears 334
Electronic/Electrical 4WS 375
Summary 336
Fail-Safe Programs 376
Review Questions 336
Four-Wheel Steering Service 376
Road Test 377
CHAPTER 37 • STEERING SYSTEM DIAGNOSIS 337
Diagnostic Trouble Code (DTC) Retrieval 377
Introduction 337
Sensors 378
Visual Inspection 338
Summary 378
Rack and Pinion Steering 341
Review Questions 378
Reciprocating Ball Steering Gears 343
Summary 345
Review Questions 345
SECTION 8: POWER STEERING 379
CHAPTER 38 • AIR BAG SERVICE 347
Introduction 347 CHAPTER 43 • POWER STEERING DESIGNS 381
Electrical System Components 347 Introduction 381
Air Bag Module 350 Types of Power-Assisted Steering Systems 381
Diagnosis 350 Main Components 383
Servicing the Air Bag System 350 Power Recirculating Ball Steering Gears 384
Summary 352 Power Rack-and-Pinion Steering Gears 386
Review Questions 352 Summary 387
Review Questions 387
CHAPTER 39 • STEERING COLUMN AND
LINKAGE SERVICE 353 CHAPTER 44 • POWER STEERING PUMPS 388
Introduction 353 Introduction 388
Steering Wheel 353 Power Steering Pump Drive Belts 388
Steering Columns 354 Power Steering Pump Designs 389
Steering Linkages 354 Power Steering Pump Operation 390
Summary 358 Summary 391
Review Questions 358 Review Questions 392

CHAPTER 40 • RECIRCULATING BALL CHAPTER 45 • ELECTRONIC STEERING SYSTEMS 393

STEERING GEAR SERVICE 359 Introduction 393
Introduction 359 Electronically Controlled Power-
Removal and Replacement 360 Steering Systems 393
Disassembly and Reassembly 360 Electronic Variable Orifice Steering 395
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x • Contents
Electric/Electronic Rack-and-Pinion System 396 Testing Input Sensors 429
Summary 398 Testing Actuators 430
Review Questions 398 Summary 431
Review Questions 431
CHAPTER 46 • GENERAL DIAGNOSIS AND SERVICE
OF POWER STEERING SYSTEMS 399
Introduction 399
Diagnosis of Power Steering Systems 399 SECTION 9: WHEEL ALIGNMENT 433
Power Steering Pump Belt Service 400
Power Steering Pump Fluid Service 403 CHAPTER 51 • ALIGNMENT GEOMETRY 435
Checking and Servicing Power Steering Introduction 435
Lines and Hoses 404 Road Variables 435
Summary 405 Camber Fundamentals 437
Review Questions 405 Caster Fundamentals 438
Steering Axis Inclination (SAI) 440
CHAPTER 47 • PUMP DIAGNOSIS AND SERVICE 406 Toe 441
Introduction 406 Other Considerations 442
Testing Power Steering Pump Pressure 406 Rear-Wheel Alignment 443
Power Steering Pump Replacement 408 Summary 445
Power Steering Pump Service 408 Review Questions 445
Summary 411
Review Questions 411 CHAPTER 52 • PRE-ALIGNMENT DIAGNOSIS
AND INSPECTION 446
CHAPTER 48 • RECIRCULATING BALL Introduction 446
POWER STEERING SERVICE 412 Road Test 446
Introduction 412 Prealignment Inspection 448
Gear Diagnosis 412 Summary 451
Power Recirculating Ball Steering Review Questions 451
Gear Replacement 412
Gear Adjustments 413 CHAPTER 53 • FOUR-WHEEL ALIGNMENT 453
Steering Gear Service 414 Introduction 453
Summary 415 Preliminary Procedure 453
Review Questions 416 Wheel Alignment Screens 455
Four-Wheel Alignment 458
CHAPTER 49 • RACK-AND-PINION POWER Rear Suspension Adjustments 463
STEERING SERVICE 417 Summary 466
Introduction 417 Review Questions 466
Diagnosis 417
Power Rack-and-Pinion Steering
Gear Disassembly 419
Power Rack-and-Pinion Steering APPENDICES 469
Gear Parts Inspection 421
Power Rack-and-Pinion Steering Gear Assembly 421 Appendix A ASE Practice Exam for
Summary 423 Suspension and Steering Systems 469
Review Questions 423 Appendix B NATEF Correlations 473
Appendix C USCS and Metric Conversions 475
CHAPTER 50 • DIAGNOSIS AND SERVICE OF Appendix D Fractions of Inches to
ELECTRONIC STEERING 425 Decimal and Metric Equivalents 476
Introduction 425 Appendix E General Torque Specifications 477
Computers 425
Diagnosis of Computer Voltage Supply Bilingual Glossary 478
and Ground Wires 428 Index 497
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Preface
THE SERIES ROM, included with each Instructor’s Manual, consists of
PowerPoint Slides for classroom presentations and a
Welcome to Thomson Delmar Learning’s TechOne, a Examview Computerized Testbank with hundreds of
state-of-the-art series designed to respond to today’s auto- questions to aid in creating tests and quizzes. Chapter-end
motive instructor and student needs. TechOne offers cur- review questions from the text have also been redesigned
rent, concise information on ASE-subject areas, combining into adaptable Electronic Worksheets, so instructors can
classroom theory, diagnosis, and repair into one easy-to-use modify questions if desired to create in-class assignments
volume. or homework.
You’ll notice several differences from a traditional text- Flexibility is the key to TechOne. For those who would
book. First, a large number of short chapters divide com- like to purchase jobsheets, Thomson Delmar Learning’s
plex material into chunks. Instructors can give tight, NATEF Standards Job Sheets are a good match. Topics
detailed reading assignments that students will find easier cover the eight ASE subjects areas and include:
to digest. These shorter chapters can be taught in almost ● Automatic Transmissions and Transaxles
any order, allowing teachers to pick and choose the mate- ● Automotive Brakes
rial that best reflects the depth, direction, and pace of their ● Automotive Electrical and Electronic Systems
individual classes. ● Automotive Engine Repair
TechOne also features an art-intensive approach to ● Automotive Engine Performance
suit today’s visual learners—images drive the chapters. ● Automotive Heating and Air Conditioning
From drawings to photos, you will find more art to better ● Automotive Suspension and Steering
understand the systems, parts, and procedures under dis- ● Manual Drive Trains and Axles
cussion. Look also for helpful graphics that draw attention Visit www.autoed.com for a complete catalog.
to key points in features like You Should Know and Inter-
esting Fact.
Just as importantly, each TechOne starts off with a sec- OTHER TITLES IN THIS SERIES
tion on Safety and Communication, which stresses safe TechOne is Thomson Delmar Learning’s latest automo-
work practices, tool competence, and familiarity with work- tive series. We are excited to announce these future titles:
place “soft skills,” such as customer communication and the ● Advanced Engine Performance
roles necessary to succeed as an automotive technician. ● Automotive Fuels & Emissions
From there, learners are ready to tackle the technical mate- Check with your sales representative for availability.
rial in successive sections, ultimately leading them to the
real test—an ASE practice exam in the Appendix.
A NOTE TO THE STUDENT
THE SUPPLEMENTS There are now more computers on a car than aboard
the first spacecraft, and even gifted backyard mechanics
TechOne comes with an Instructor’s Manual that long ago turned their cars over to automotive professionals
includes answers to all chapter-end review questions and a for diagnosis and repair. That’s a statement about the
complete correlation of the text to NATEF standards. A CD- nation’s need for the knowledge and skills you’ll develop as

xi
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xii • Preface
you continue studies. Whether you eventually choose a cutting-edge workforce, you’ll fill a need, and, even better,
career as an ASE-certified technician, service writer or man- you’ll have a career to feel proud of.
ager, or automotive engineer—or even decide to open
your own shop—hard work will give you the opportunity Best of luck in your studies,
to become one of the 840,000 automotive professionals in The Editors of Thomson Delmar Learning
the United States. As a member of a technically-proficient,
11662 FM.qxd 4/20/05 1:00 PM Page xiii

About the Author

Jack Erjavec, a master-certified ASE technician and Delmar Learning for business, industry, government, and retail
professor emeritus at Columbus State Community Col- automotiove materials, as well as a professional consultant for
lege in Columbus, Ohio, has become a fixture in the several automotive manufacturers. He is a long-time affiliate of
automotive textbook world with more than 30 works the North American Council of Automotive Teachers (NACAT),
to his credit. In addition to his bestselling comprehen- having served on the board of directors and as executive vice-
sive text, Automotive Technology, Jack is also series edi- president, and now as Vice-President of Marketing. Jack is also
tor of Thomson Delmar Learning’s popular Today’s associated with a number of professional organizations, includ-
Technician series and the new TechOne automotive ing the Society of Automotive Engineers, and remains active in
series. the industry. In his free time, he most cherishes spending time
In addition to assuming these editorships, Jack with his family: Rose, Megan, Craig, Hannah, Grace, Moira, Judah,
was the Product Development Manager at Thomson and Erin.

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Acknowledgments
I’d like to thank the following reviewers, whose techni- Russ Molaski
cal expertise was invaluable in creating this text: North East Wisconsin Tech College
Green Bay, WI
David Ames
Evergreen Valley College Chris Perales
San Jose, CA Texas State Technical College
Waco, TX

R.J. Ehlers Dan Perrin

Linn-Benton Community College Trident Technical College
Albany, OR Charleston, SC

Randy Jacobsen Christopher VanStavoren

Southwestern Michigan College Penn College of Technology
Dowagiac, MI Williamsport, PA

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Features
of the Text
TechOne includes a variety of learning aids designed to
encourage student comprehension of complex automo-

1
tive concepts, diagnostics, and repair. Look for these helpful SECTION OBJE
features: After you have
CTIVES
tents of this sec read, studied, and
tion, you should practiced the
be able to: con-
■ Wear proper clo
thing for workin
use eye, hand, and g in a shop and
hearing protec
needed. tion when

Section
■ Maintain a safe
work environme
■
nt in the shop.
Lift and carry hea
vy objects safely
sonal injury. to avoid per-

Section Openers provide students with a ■ Identify the typ

e of fire extinguis
her to use on a
specific fire and
extinguish the
Section Table of Contents and Objectives to fires that may occ
ur in the shop.
common types
of
focus learners on the section’s goals. Safety a
■ Demonstrate the
proper driving
tec
Communnicdati
while road testin hniques
g a vehicle.
■ Discuss basic saf
on mon sense dic
ety rules and des
tates these rule
cribe how com
-
Chapter 1 Safe Wo ■ Explain the purpo
s.
rk Practices se of a Material
Safety Data
Chapter 2 Measu Sheet (MSDS).
ring Systems, ■ Explain the princi
Fasteners, and Measu ples of hazard
(or information) communicatio
ring and worker “rig n
Tools ■ List the basic un
ht-to-know” law
s.
its of measure
Chapter 3 Tools ume in the me for length and
vol-
of the Trade ■
tric and U.S. cus
tomary system
s.
Inspect and use
Chapter 4 Worki hand tools safely
ng as a Suspension ■ Identify and des .
cribe the purpo
and Steering Speciali commonly use se and use of
st d power tools.
Interesting Facts spark student attention with ■ Operate powe
r tools safely.
■ Operate shop ho
industry trivia or history. Interesting facts appear ■ Identify and use
ists and jacks saf
ely.
the major measu
on the section openers and are then scattered instruments use
d during suspen
ring tools and
sion and steer-
ing work.
throughout the chapters to maintain reader ■ Identify and des
cribe the purpo
interest. special tools use
d for suspensio
se and use of
n and steering
system service.
■ Identify and use
the electrical tes
diagnostics. t tools used for
■ List the princip
al methods, or
soning and exp causes, of chemic
lain how to avo al poi-
id them.
■ Use all cleaning
equipment safe
comply with all ly and properly
requirements for and
ing of hazardous handling and disp
materials. os-

xv
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Chapter
INTRODUCTI
ON
4
sful automotiv
e technician you
need to
ted
Working as a
Suspension
and Steering
Specialist
An Introduction orients readers at the begin-
ning of each new chapter. Technical Terms are
bolded in the text upon first reference and are
defined.

To be a succes d, and be commit

d trainin g, a desire to succee d em plo yee. A
have goo cian and a goo
goo d tec hni to ma ke
to become a others and strives just in
works well with g is not
good employee . The required trainin 4-1 )
ces sful ure
the business suc technicians (Fig
omotive. Good math skills. The
se
the field of aut rea ding, writing, and te-
e goo d the ma
need to hav erstand and use
you to better und ll as pro-
skills will allow textbooks, as we
vice manuals and communications with
rial found in ser ics for goo d
the bas
vide you with
others.
customers and
N
COMPENSATIO ording to their
abili-
typically paid acc cians are paid by
Technicians are hni
st ofte n, new or apprentice tec bus ine ss wh ile
ties. Mo e and the
learning the trad a master
the hour.They are usually spent working with tice
paid. Tim e is As an app ren
being jobs.
doing low-skilled e on more
technician or n more and tak
or she can ear trated a satis-
learns more, he hni cian s have demons
complex jobs. On
ce tec their own
responsible for
skills, they are go on flat rate.
factory level of wa ges or they can
her paid
work and receive
hig a technician is
system in which a flat rate time
Flat rate is a pay y do. Each job has less of how
t of wo rk the
for the amoun t time, regard
is based on tha this system
(Figure 4-2). Pay .To explain how
complete the job o is paid $15.00
per flat
long it took to hni cian wh e good
works, let us loo
k at a tec
of 3 hou rs, the techni- need to hav
a flat rate tim e
long it od technicians
rate hou r. If a job has
job, regardless
of how Figure 4-1. Go wr itin g, and math ski
lls.
d $45.00 for the hnicians beat the
flat rea din g,
cian will be pai Experienced tec
com ple te it. pay is bas ed on
took to the tim e.T heir weekly 33
all of
rate time nearly

Chapter 13 Tir
e and Wheel Se
You Overtorqueing
the lug nuts is for objects tha
rvi ce • 145
Should the most
common cause t might have
Know of disc brake rot tread. More freq become imbedd
distortion. or uent inspection ed in the
rapid or extrem s are recomme
e temperature nded when
road sur faces changes occur,
are rough or or
debris. occasionally litte where
TIRE CARE To clean tires, use
red with
Rinse thoroughl a mild soap-and-
To maximize tire y with clear water solution
per formance, ins water. As rub only.
of improper infl pect them for becomes harder ber dries, it
ation and une signs and the tire will
be checked for ven wear. Tires ance characteri lose some of its
cuts, stone bru should also stics. per form-
ises, abrasions, When storing tire
blisters, and s, lay them flat
floor. Store them on a clean, dry,
in the dark. Direct oil-free
sunlight is hard
on tires.
SUMMARY
You Should Know informs the reader ■ Inspect tires for
signs of improp
whenever special safety cautions, warn- wear. Tires sho
uld also be che
er inflation and
cked for cuts,
uneven
■ To equalize tire
abrasions, blisters bruises,
, and for stones wear, tires sho
ings, or other important points deserve might have bec
ome imbedded
or other object
in the tread.
s that ■
use a tire change
There are thre
uld be rotated
r to demount and . Always
e popular metho remount tires.
emphasis. type plug, cold
patch repair, and
ds of tire repair:
hot patch repair.
head-

A Summary concludes each chap- REVIEW QUES

TIONS
ter in short, bulleted sentences. Review 1. Why is tire rota
tion recomme
Questions are structured in a variety of turers?
2. Describe the
nded by most
manufac-
C. Both Techni
procedure for usin cian A and Techni
formats, including ASE style, challenging ture in a tire. g a plug to sea
l a punc- D. Neither Techni
5. All of the foll cian A nor Tec
cian B
3. Why should
n’t mineral oils owing statement hnician B
students to prove they’ve mastered the tires?
4. Technician
be used to clea
n or treat A. A cold patch s are true
should be stitche except:
face of the carcas d to the inner
A uses tire sea s. sur-
material. valve stem to rep
air
lant injected thro
Technician B use a tire punctured in the tread
ugh the B. A tread pun
cture that is less
eter is repairable than 1/4 inch in
s tire sealant are diam-
valve stem to injected through a. C. Wheel balanc
.
repair a tire pun the ing is required
Who is correct? ctured in the are installed. only when new
sidewall. tires
A. Technician A D. For best res
ults, punctures
B. Technician B from inside the should be rep
tire. aired

xvi
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An ASE Practice Exam is found in the

Appendix A
Appendix of every TechOne book, followed by a
Bilingual Glossary, which offers Spanish trans-
lations of technical terms alongside their English
counterparts.
E EXAM FOR G SYSTEMS
ASE PRACTICSPENSION AND STEERIN
MANU AL SU ing,”“whining,”
or “howling”) tha
t
lic noise (“moan is present 5. A cyc ed and
d on a sports with road spe sed by
rims are installe changes pitch tion may be cau
s and new alloy der and vehicle is in mo
1. After new tire ut steering wan whenever the
complains abo . Technician ing exc ept :
car, the owner wh ile bra king any of the follow l gears.
in eith er direction linings. ntia
steering pul l
on the fron t bra ke A. worn differe
y be brake fluid e a rings.
A says there ma nt rims may hav B. rear axle bea
cian B say s the replaceme is cor rec t? orre ct driv eshaft runout.
Techni rims.Who C. inc
n the orig inal tread pattern.
different offset tha D. off-road tire
ring may be cau
sed by low
A. Technician A A says hard stee valve in
6. Technician ck flow control
B. Technician B cian B rau lic pre ssu re due to a stu ring may be
cian A and Techni hyd B say s hard stee
C. Both Techni cian B the pump. Tec
hni cian
to a worn steering
cian A nor Techni raulic pressure due correct?
D. Neither Techni a rear-wheel caused by low hyd
edg e of the left front tire on cause or hou sing bore.Who is
2. The outside hnician A says the gear piston ring
ly scalloped. Tec s the cause A. Technician A
drive car is bad ts. Technician B say
bal l join
could be wo rn
Who is correc t? B. Technician B cian B
ct tire pressure. cian A and Techni
could be incorre C. Both Techni cian B
cian A nor Techni
A. Technician A D. Neither Techni hnician A says
a
B. Technician B ing tire tread we Tec ar,
-of-round
cian B 7. While discuss
indicates an out
cian A and Techni tire we ar
C. Both Techni cian B scalloped pattern
of
ven wear on one
side
cian A nor Techni hnician B says une
D. Neither Techni heel drive sedan s. The
says the wheel or tire.Tec variation.Who is
correct?
of a large rear-w icate radial force
3. The owner ing low -speed turn of a tire may ind
t tire s squ eal loudly dur is: A. Technician A
fron dition
cause of this con
most probable B. Technician B cian B
itive camber. cian A and Techni
A. excessive pos C. Both Techni cian B
ter adj ustme nt. cian A nor Techni
B. negative cas tion (SAI). D. Neither Techni noises only
ering axis inclina makes chattering
C. improper ste 8. A front-whee
l driv e car
n A says the pro
blem
ing angle. t turn.Technicia
D. improper turn vehicle is ding.

Bilingual Glossa
dder when the during a hard righ by an upper spring seat bin
has a severe shu chnician A cau sed sed by a
4. A mini pickup d in the bed.Te is probably is probably cau
stop with a loa Technician s the problem
started from a spr ing eye s. Technician B say . Who is cor rec t?
m may be worn ho is t bea ring
says the proble torque wrap-up.W

ry
defective stru
m may be axle
B says the proble A. Technician A
correct? B. Technician B
A. Technician A C. Both A and
B
B
B. Technician B cian B D. Neither A nor
cian A and Techni
C. Both Techni cian B
cian A nor Techni
D. Neither Techni Actuator A
action in responcontrol device that delive
Actuador Dis se to an electrical signal. rs mechanical Ammeter The
positivo de con
mecánica en resp trol
uesta a una señ que proporciona acción rent flow in a circinstrument used to measure
al eléctrica. Amperímetro uit. electrical cur-
Additive In lub corriente eléctric Instrumento que se usa para
a en un circuito medir el flujo de
give it certain ricating oils, a material add .
engine oil to less pro per ties; for examp ed to the oil to Ampere The
le, a ma
low temperatu en its tendency to congeaterial added to called an amp. unit for measuring electrical
res. l or thicken at Amperio Uni current; usually
Aditivo En ace
aceite para dar ites lub rica ntes, material que mente se conocedad para medir la corriente eléc
que se agrega alle ciertas propiedades; por ejemse agrega al como amp. trica. General-
al congelamientoaceite del motor para disminu plo, material Analog signal
o espesamiento ir su tendencia giv A voltage sig
a bajas temperatu en range (from hig nal tha
ras. between). h to low, includt varies within a
Air bag system ing all points
vehicle’s on-boa A system that uses impact Señal analógica in
rd com sen sor ran go Señal de voltaje
nylon bag in the put er, an inflation s, the (de alto a bajo, inc que varía dentro
to protect the ste ering column
and
mo dul e, and a dio s). luid os tod os los puntos intede un
driver and pas ins tru rme -
collision. senger during ment panel Anti-friction bea
Sistema de bol a head-on
impacto, la com sa de aire Sistema que usa tion. This type of ring A bearing designed
put to bearing norma to reduce fric-

Index
de inflado, y una ado ra a bordo del sen sores de red uce the fric lly uses ball or roll
vehícul
dirección y el bolsa de fibra sintética en o, el módulo Cojinete antifri tion. er inserts
conductor y al pas tablero de inst la columna de ción. Este tipo dección Cojinete diseñado par
rum de rodillo para redcojinete normalmente usa inse a reducir la fric-
ajero durante una entos para proteger al
colisión de frente. ucir la fricción. rtos de bola o
Allen wrench Antilock brakin
es Allen wre
are used to tigh
ten
nches or hex-he
ad devices at eac g system (ABS) A ser
and loosen setscre wre nches h wh eel that control ies of
machined hex ws vent wheel loc braking action sensing
integral carrier Llaves Allen -shaped recess in the bolt or and fit into a Sistema de fren kup. to pre-
disassembling usan para apretaLas llaves Allen o de cabezascrew. sores en cada rueos antibloqueo Serie de
smission Fluid differentials, 183 r y aflo hex ago da disp
Automatic Tran removable
un hueco maqui jar torn illos de presión nal se prevenir el bloque que controlan la acc osit ivos sen-
25 (ATF), 293 disassem blin g nad o con forma hex y aju sta rlos en o de las ruedas. ión de fren ado para
air wrenches, tials, 187
tornillo. agonal en el per
smissions, 39, carrier differen
A alarms, fire, 5 automatic tran no o AWG Americ
e wea r, rear axle bearings, nm ent . See adju sting; 225 4W D syst ems, 355 designate wire an Wire Gauge System. The
abrasiv alig r ratio s, 166 ing, 178 All-Wheel Drive size sys tem
ent e gea diag nos . used to
154, 155 misalig nm
wrenches, 19
final driv
assembly),
leak s, provides power (AWD) A driveline setup AWG Sistema
ke systems), Allen (hex-head) AWD (all- flex plates (clutch axle ratios, 40 to all four wheel that constantly tema que se usa Estadounidense de Calibre de
ABS (antilock bra AWD Propulsión s. para designar el Alambre. Sis-
hee l-dr ive. See 225 axle sha fts, 115, 126 total. Configurac tam
102 all-w que proporcion año del alambre.
l, 102 wheel-drive) veh 49
icles
solenoid testing,
78 balancing, 145 a potencia constan ión de la unidad motriz
drive axle remova te a las cuatro rue Axial Having
179 rent (AC), nician jobs. See bearing design
s, 127 axis or rotation the same direction or being
lubricant leaks, alternating cur g, 307 automotive tech Alternating cur
das.
. parallel to the
servicing CV join
ts, 106
alum inu m case, repairin work practices C-locks on, 150 ren t (AC ) Ele
Axial Con la mis
sor circ uits , 61, 77 Wir e Gau ge (AWG) otiv e tran smi ssions. See stru ctio n, 115 direction betwe
en positive and ctrical current that changes
ma dirección o
paralelo al eje de
speed sen Americ an autom con Corriente alterna
current), 49 negative. rotación.
AC (alternating system, 69 transmissions diagnostics, 131 ems, 330, ción entre positivo Corriente eléctrica que cam
Axi al load A
e, 7 AWD (all-wheel-d
rive) vehicles, 4WD and AWD
syst y negativo. bia de direc- allel to the axis type of load placed on a bea
accident respons ammeters, 49 , 342. See also Carga axial of the rotating shaft. ring that is par-
rs, 56 ltim eter s, 68 327 , 329 , 332 343, 360
actuato
56
mu
tron ics, 66 4WD (fou r-w hee l-dr ive)
installin g, 141 paralelo al eje delTipo de carga que se coloca
A/D converters, testing elec 382 árbol giratorio. en un cojinete
250, 345 49, 64 vehicles IRS systems, 128
adjusting, 136, amperes (amps),
misalignment 56 axle housings, 355 removal, 141
alignment. See 136 , analog signals, s, 102 out
backlash in gea rs, 45,
anti-lock bra ke syst em diagnos tics , 353 runout of. See run D
(RW
176 lubricant leaks,
179 fluid leaks, 342 t seals, servicing
hou sing (clu tch serv icin g CV joints, 106 insp ecti ng general shif veh icle s), 155
bell uits, 61, 77
assembly), 258 speed sensor circ ms, 33 controls, 346 servicing, 140
243, 297 progra rentials, 329, shaft angle, me
asuring and
clutch linkages, apprenticeship limited-slip diffe
rings, 231, , 32 adjusting, 147
clutch release bea ASE certification 355
systems, 331 ,
ling , 142 shif t-on -the -fly slip join ts, 117
259 assemb
lies, 260 types of, 117, 126 universal
endplay, 45, 152 clutch assemb 348
units, 209 inspection, universal joints.
See
FWD final drive clutch packs, 218 ts, 144 steering system
gears, in gen eral
ch
, 45
link age s, dou ble Car dan
ier
join
diffe ren tials,
344
whe el insp ecti on,
joints
visual insp ecti on, 138 A comprehensive Index helps instructors and
hydraulic clut integral carr tire and
axles
250
inst alla tion ang les of U-joints, rem
186
ova ble carr ier
346
tran sfer case s. See transfer
axles. See drive students pinpoint information in the text.
ems
148 differentials, 188 cases, AWD syst B
preload, 193 ations to, 361 g, 45, 136, 176,
pinion bearing transaxles, 316 typical modific backlash, adjustin
ion gea r dep th, 191, 193 tran sfer case s, 370 visc ous cou plings, 335 194
pin s, 46, e Gauge) 77
of gea r train ssio ns, 319 eric an Wir kup ligh ts, 60,
preloading transmi AWG (Am bac
shafts, 145
137, 177, 182, 193 universal joints,
142 system, 69 balancing drive
and final drive Transmission axle housings, 163 rings, 44
rear differential ATF (Automatic gral carrier
ball bea
sions, 344
units, 191, 209 Fluid), 293 assembling inte ball joints, suspen
gear rings, 127, 152
ring and pinion atomic structu
re, 48 differentials, 186 ball-type axle bea
, 215, 217 ovable carrier ) CV joints, 90,
backlash, 194 Aub urn differentials assembling rem ball-type (Rzeppa
bea ring pre load, 209 ran ge feat ure (digital diffe ren tials , 188 91, 92
side auto -slip
ent , 113 eter s), 68 g limi ted replaci ng, 106
wheel alignm multim checkin
s, 4WD systems, ing hubs, 334 differentials with
out
wear, 93
wheel bearing automatic lock , 217
345, 360 installing, 358 removing from 399
, 7 g, 357
air bag system removin
air rachets, 25 xvii
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