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Classroom Manual Table of Contents 1. Suspension and Steering Systems Introduction, Frames and Unitized Bodies, Front Suspension Systems, Rear Suspension Systems, Tires, Wheels, and Hubs, Shock Absorbers and Struts, Computer-Controlled Suspension Systems and Shock Absorbers, Steering Systems, Wheel Alignment, Steering Axis Inclination, Summary, Review Questions. 2. Basis Theories Introduction, Newton's Laws of Motion, Work and Force, Energy, Energy Conversion, Inertia, Momentum, Friction, Mass Weight and Volume, Torque, Power, Principles Involving Tires and Wheels in Motion, Principles Involving Liquids and Gases, Atmospheric Pressure, Vacuum, Venturi Principle, Summary, Review Questions. 3. Wheel Bearings Introduction, Bearing Loads, Ball Bearings, Roller Bearings, Seals, Wheel Bearings, Rear Axle Bearings, Bearing Lubrication, Summary, Review Questions. 4. Tires and Wheels Introduction, Tire Design, Tire Ply and Belt Design, Tire Tread Design, Tire Manufacturing Defects, Tire Ratings and Sidewall Information, Specialty Tires, Replacement Tires, Tire Valves Tire Chains, Compact Spare Tires, Run-Flat Tires, Tire Pressure Monitoring Systems, Tire Contact Area, Tire Placard and Inflation Pressure, Nitrogen Tire Inflation, Tire Motion Forces, Wheel Rims, Static Wheel Balance Theory, Dynamic Wheel Balance Theory, Noise, Vibration, and Harshness, Summary, Review Questions. 5. Shock Absorbers and Struts Introduction, Shock Absorber Design, Shock Absorber Operation, Gas-Filled Shock Absorbers and Struts, Heavy-Duty Shock Absorber Design, Shock Absorber Ratios, Strut Design, Front Suspension, Shock Absorber and Strut Design, Rear Suspension, Travel Sensitive Struts, Adjustable Struts, Load-Levelling Shock Absorbers, Electronically Controlled Shock Absorbers and Struts, Summary, Review Questions. 6. Front Suspension Systems Introduction, Suspension System Components, Short-and-Long Arm Front Suspension Systems, MacPherson Strut Front Suspension System Design, Modified MacPherson Strut Suspension, High Performance Front Suspension Systems, Torsion Bar Suspension, Curb Riding Height, Front Spring Sag Curb Riding Height and Caster Angle, Spring Sag Curb Riding Height and Camber Angle, Summary, Review Questions. 7. Rear Suspension Systems Introduction, Live Axle Rear Suspension Systems, Semi-Independent Rear Suspension Systems, Independent Rear Suspension Systems, Curb Riding Height, Spring Sag Curb Riding Height and Caster Angle, Summary, Review Questions. 8. Computer-Controlled Suspension Systems Introduction, Programmed Ride Control System, Electronic Air Suspension System Components, Electronic Air Suspension System Operation, Air Suspension System Design Variations, Vehicle Dynamic Suspension (VDS) System, Electronic Suspension Control (ESC) System, Integrated Electronic Systems and Networks, Vehicle Stability Control, Active Roll Control Systems, Active Cruise Control (ACC) Systems, Lane Departure Warning Systems, Collision Mitigation Systems, Telematics, Summary, Review Questions. 9. Steering Columns and Steering Linkages Introduction, Conventional Nontilt Steering Column, Tilt Steering Column, Electronic Tilt/telescoping Steering Column, Active Steering Column, Steering Linkage Mechanisms, Steering Damper, Summary, Review Questions. 10. Power Steering Pumps Introduction, Power Steering Pump Drive Belts, Types of Power-Assisted Steering Systems, Power Steering Pump Design, Power Steering Pump Operation, Hybrid Vehicles and Power Steering Systems, Various Types of HEVs, Fuel Cell Vehicles, Summary, Review Questions. 11. Recirculating Ball Steering Gears Introduction, Manual Recirculating Ball Steering Gears, Power Recirculating Ball Steering Gears, Summary, Review Questions. 12. Rack and Pinion Steering Gears Introduction, Manual Rack and Pinion Steering Gear Main Components, Steering Gear Ratio, Manual Rack and Pinion Steering Gear Mounting, Advantages and Disadvantages of Rack and Pinion Steering, Power Rack and Pinion Steering Gears, Types of Rack and Pinion Steering Gears, Electronic Variable Orifice Steering, Saginaw Electronic Variable Orifice Steering, Rack-Drive Electronic Power Steering, Electronic Power Steering System Operation, Column-Drive Electronic Power Steering, Column-Drive Electronic Power Steering Operation, Pinion-Drive Electronic Power Steering, Active Steering System, Steer-By-Wire Systems, Summary, Review Questions. 13. Four-Wheel Steering Systems Introduction, Electronically Controlled Four-Wheel Steering, Input Sensors, Four-Wheel Steering System Operation, Quadrasteer Four-Wheel Steering Systems, Quadrasteer Four-Wheel Steering System Operation, Rear Active Steering System, Four-Wheel Active Steering (4WAS), Summary, Review Questions. 14. Frames and Frame Damage Introduction, Types of Frames and Frame Construction, Unitized Body Design, Vehicle Directional Stability, Types of Frame Damage, Summary, Review Questions. 15. Four Wheel Alignment Part I Introduction, Wheel Alignment Theory, Importance of Four Wheel Alignment, Rear Wheel Alignment and Vehicle Tracking Problems, Types of Wheel Alignment, Computer Alignment Systems, Camber Fundamentals, Driving Conditions Affecting Camber, Caster Fundamentals, Safety Factors and Caster, Steering Terminology, Summary, Review Questions. 16. Four Wheel Alignment Part II Introduction, Steering Axis Inclination (SAI) Definition, SAI Purpose, SAI and Safety Factors, Scrub Radius, Wheel Setback, Toe Definition, Toe setting for Front-Wheel- Drive and Rear-Wheel-Drive Vehicles, Toe Adjustment and Tire Wear, Turning Radius, Rear Wheel Alignment, Summary, Review Questions. Shop Manual Table of Contents 1. Safety Introduction, Occupational Safety and Health Act, Shop Hazards, Shop Safety Rules, Air Quality, Shop Safety Equipment, Shop Layout, Safety in the Automotive Shop, General Shop Safety, Personal Safety, Electrical Safety, Gasoline Safety, Fire Safety, Vehicle Operation, Housekeeping Safety, Air Bag Safety, Lifting and Carrying, Hand Tool Safety, Lift Safety, Hydraulic Jack and Safety Stand Safety, Power Tool Safety, Compressed Air Equipment Safety, Cleaning Equipment Safety and Environmental Considerations, Hazardous Waste Disposal, Summary, Case Study, Terms to Know, ASE-Style Review Questions, Job Sheets. 2. Typical Shop Procedures Using Suspension and Steering Equipment, Measuring Systems, Basic Diagnostic Procedure, Suspension and Steering Tools, Hydraulic Pressing and Lifting Equipment, Suspension and Steering Service Diagnostic and Measurement Tools, Employer and Employee Obligations, National Institute for Automotive Service Excellence (ASE) Certification, Service Manuals, Summary, Case Studies, Terms to Know, ASE-Style Review Questions, Job Sheets. 3. Wheel Bearing and Seal Service Diagnosis of Bearing Defects, Service and Adjustment of Tapered Roller Bearing-Type Wheel Bearings, Wheel Hub Unit Diagnosis, Front Drive Axle Diagnosis, Drive Axle Removal, Special Procedures for Drive Axle Removal, Front Wheel Hub Unit Removal and Replacement, Rear Axle Bearing and Seal Service Rear-Wheel Drive Cars, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 4. Tire and Wheel Servicing and Balancing Tire Noises and Steering Problems, Tire Rotation, Tire and Wheel Service, Tire and Wheel Service Precautions, Wheel Rim Service, Tire Remounting Procedure, Diagnosing and Servicing Tire Pressure Monitoring Systems, Tire and Wheel Runout Measurement, Tread Wear Measurement, Preliminary Wheel Balance Checks, Tire Inflation Pressure, Static and Dynamic Wheel Balance Procedure, Electronic Wheel Balancers with Lateral Force Measurement (LFM), and Radial Variation Capabilities, On-Car Wheel Balancing, Vibration Diagnosis, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 5. Shock Absorbers and Strut Diagnosis and Service Shock Absorber Visual Inspection, Shock Absorber or Strut Bounce Test, Shock Absorber Manual Test, Air Shock Absorber Diagnosis and Replacement, Shock Absorber Replacement, Diagnosis of Front Spring and Strut Noise, Strut Removal and Replacement, Removal of Strut from Coil Spring, Strut Disposal Procedure, Installation of Coil Spring on Strut, Installation of Strut-and-Spring Assembly in Vehicle, Rear Strut Replacement, Installing Strut Cartridge, Off-Car, Installing Strut Cartridge, On-Car, Diagnosis of Electronically Controlled Shock Absorbers, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 6. Front Suspension System Service Curb Riding Height Measurement, Front Suspension Diagnosis and Service, Control Arm Diagnosis and Service, Removing and Replacing Longitudinally Mounted Torsion Bars, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 7. Rear Suspension Service Rear Suspension Diagnosis and Service, Lower Control Arm and Ball Joint Diagnosis and Replacement, Rear Leaf-Spring Diagnosis and Replacement, Track Bar Diagnosis and Replacement, Stabilizer Bar Diagnosis and Service, Rear Suspension Tie-Rod Inspection and Replacement, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 8. Computer-Controlled Suspension System Service Preliminary Inspection of Computer-Controlled Suspension Systems, Programmed Ride Control System Diagnosis, Electronic Air Suspension Diagnosis and Service, Servicing and Diagnosing Vehicle Dynamic Suspension Systems, Diagnosis of Electronic Suspension Control Systems, Scan Tool Diagnosis of Electronic Suspension Control Systems, Diagnosis of Vehicle Networks, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 9. Steering Column and Linkage Diagnosis and Service Air Bag Deployment Module Steering Wheel and Clock Spring Electrical Connector Removal and Replacement, Steering Column Service, Collapsible Steering Column Inspection, Tilt Steering Column Disassembly, Tilt Steering Column Inspection and Parts Replacement, Tilt Steering Column Assembly, Steering Column Flexible Coupling and Universal Joint Diagnosis and Service, Steering Column Diagnosis, Steering Linkage Diagnosis and Service, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 10. Power Steering Pump Diagnosis and Service Power Steering Pump Belt Service, Power Steering Pump Fluid Service, Power Steering Pump Diagnosis, Power Steering Pump Service, Inspecting and Servicing Power Steering Lines and Hoses, Power Steering Hose Replacement, Hybrid Electric Vehicle (HEV) Electrohydraulic Power Steering (EHPS) Diagnosing and Servicing Procedures, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 11. Recirculating Ball Steering Gear Diagnosis and Service Power Recirculating Ball Steering Gear Diagnosis, Power Recirculating Ball Steering Gear Replacement, Power Recirculating Ball Steering Gear Adjustments, Power Recirculating Ball Steering Gear Oil Leak Diagnosis, Power Recirculating Ball Steering Gear Seal Replacement, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 12. Power Rack and Pinion Steering Gear Diagnosis and Service Manual or Power Rack and Pinion Steering Gear On-Car Inspection, Manual or Power Rack and Pinion Steering Gear Removal and Replacement, Manual Rack and Pinion Steering Gear Diagnosis and Service, Power Rack and Pinion Steering Gear Diagnosis and Service, Diagnosis of Power Steering and Suspension Systems, Diagnosis of Magnasteer Systems, Diagnosis of Rack-Drive Electronic Power Steering, Diagnosis of Column-Drive Electronic Power Steering, Active Steering System Preliminary Diagnosis, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 13. Electronic Four-Wheel Steering Diagnosis and Service Preliminary Inspection, Quadrasteer Diagnosis, Electronically Controlled Four-Wheel Steering Diagnosis, Rear Steering Actuator Service, Diagnosis of Four-Wheel Active Steering (4WAS) System, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 14. Frame Diagnosis and Service Indications of Frame Damage, Frame Diagnosis, Checking Frame Alignment, Measuring Unitized Body Alignment, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 15. Four Wheel Alignment Procedure Wheel Alignment Preliminary Diagnosis and Inspection, Four Wheel Alignment with Computer Alignment Systems, Wheel Alignment Screens, Adjustment Screens, Diagnostic Drawing and Text Screens, Checking Toe Change and Steering Linkage Height, Bent Front Strut Diagnosis, Case Study, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets. 16. Four Wheel Alignment Adjustments Wheel Alignment Procedure, Camber Adjustment, Caster Adjustment, Caster Adjustment Procedure, Setback Measurement and Correction Procedure, Steering Axis Inclination (SAI) Correction Procedure, Toe Adjustment, Steering Wheel Centering Procedure, Causes of Improper Rear Wheel Alignment, Rear Suspension Adjustments, Rear Wheel Tracking Measurement with a Track Gauge, Case Study, Terms to Know, ASE-Style Review Questions, ASE Challenge Questions, Job Sheets.
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