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AUTOMOTIVE STEERING, SUSPENSION, AND ALIGNMENT EIGHTH EDITION James D. Halderman A01_HALD4642_08_SE_FM.indd 1 13/11/19 5:08 PM
AUTOMOTIVE STEERING,
SUSPENSION, AND ALIGNMENT
E I G H T H E D I T I O N
James D. Halderman
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Director of Product Management: Linea RoweProduct Manager, Trades, Hospitality, & Careers: Derril TrakaloSenior Analyst, HE Global Content, Trades & Hospitality: Tara WarrensAnalyst, HE Global Content, Careers & Professional: Bridget DalyManager Content HE, Careers & Professional: Jenifer NilesDirector, Digital Studio & Content Production: Brian HylandManaging Content Producer: Jennifer SargunarManaging Producer, Teacher Education & Careers: Autumn BensonContent Producer (Team Lead): Faraz Sharique AliPermissions Editor: Jenell ForschlerCover Design: Carie Keller, SPiCover Credit: Courtesy of ASE; Henrik5000/E+/Getty imagesFull-Service Management and Composition: Integra Software Service Pvt. Ltd.Printer/Binder: LSC Communications,Inc.Cover Printer: LSC Communications,Inc.Text Font: Helvetica Neue LT W1G
ISBN-10: 0-13-567464-6ISBN-13: 978-0-13-567464-2
Copyright © 2021, 2017, 2014, by Pearson Education, Inc. 221 River Street, Hoboken, NJ 07030. All Rights Reserved. Printed in the United States of America. This publication is protected by copy-right, and permission should be obtained from the publisher prior to any prohibited reproduction, storage in a retrieval system, or transmission in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise. For information regarding permissions, request forms and the appropriate contacts within the Pearson Education Global Rights & Permissions department, please visit www.pearsoned.com/permissions/.
Library of Congress Cataloging-in-Publication Data
Names: Halderman, James D., author.Title: Automotive steering, suspension & alignment / James D. Halderman.Other titles: Automotive steering, suspension and alignment | Automotive steering, suspension and alignmentDescription: Eighth edition. | Hoboken : Pearson, 2021. | Includes index. | Summary: “This comprehensive textbook is divided into sections that correspond to the A4 area of certifications as specified by the National Institute for Automotive Service Excellence (ASE). The areas of the ASE material certification test are listed in the objectives at the beginning of each chapter, and all laboratory worksheets are correlated to the ASE Task Sheets”—Provided by publisher.Identifiers: LCCN 2019047553 (print) | LCCN 2019047554 (ebook) | ISBN 9780135674642 (paperback) | ISBN 9780135758380 (epub)Subjects: LCSH: Automobiles—Steering-gear. | Automobiles—Springs and suspension. | Automobiles—Wheels—Alignment.Classification: LCC TL259 .H35 2021 (print) | LCC TL259 (ebook) | DDC 629.2/4—dc23 LC record available at https://lccn.loc.gov/2019047553 LC ebook record available at https://lccn.loc.gov/2019047554
Unless otherwise indicated herein, any third-party trademarks, logos, or icons that may appear in this work are the property of their respective owners, and any references to third-party trademarks, logos, icons, or other trade dress are for demonstrative or descriptive purposes only. Such references are not intended to imply any sponsorship, endorsement, authorization, or promotion of Pearson’s prod-ucts by the owners of such marks, or any relationship between the owner and Pearson Education, Inc., authors, licensees, or distributors.
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iii
BRIEF CONTENTS chapter 1 Service Information, Work Orders, and Vehicle Identification 1
chapter 2 Tools and Safety 9
chapter 3 Environmental and Hazardous Materials 42
chapter 4 Tires and Wheels 53
chapter 5 Tire-Pressure Monitoring Systems 78
chapter 6 Tire and Wheel Service 92
chapter 7 Suspension System Components and Operation 117
chapter 8 Front Suspension and Service 142
chapter 9 Rear Suspension and Service 172
chapter 10 Electronic Suspension Systems 184
chapter 11 Electronic Stability Control Systems 201
chapter 12 Steering Columns and Gears 210
chapter 13 Steering Linkage and Service 228
chapter 14 Hydraulic Power Steering Systems 246
chapter 15 Electric Power Steering Systems 271
chapter 16 Wheel Bearings and Service 280
chapter 17 DriveShafts and CV Joints 299
chapter 18 DriveShaft and CV Joint Service 310
chapter 19 Wheel Alignment Principles 324
chapter 20 Alignment Diagnosis and Service 340
chapter 21 Vibration and Noise Diagnosis and Correction 372
APPENDIX 1 SAMPLE SUSPENSION AND STEERING (A4) ASE-TYPE CERTIFICATION TEST 386
APPENDIX 2 2017 ASE CORRELATION CHART 390
GLOSSARY 394
INDEX 404
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CONTENTSchapter 1
SERVICE INFORMATION, WORK ORDERS, AND VEHICLE IDENTIFICATION 1
■■ Learning Objectives 1■■ Key Terms 1■■ Owner’s Manuals 1■■ Service Information 2■■ Technical Service Bulletins 2■■ Recalls and Campaigns 2■■ Work Order 3■■ Service Records 3■■ Additional Information 5■■ Parts of a Vehicle 5■■ Front-Wheel Drive Versus Rear-Wheel Drive 5■■ Vehicle Identification 5■■ Vehicle Safety Certification Label 7■■ VECI Label 7
Summary 7review QueStionS 8Chapter Quiz 8
chapter 2
TOOLS AND SAFETY 9■■ Learning Objectives 9■■ Key Terms 9■■ Threaded Fasteners 9■■ Hand Tools 13■■ Screwdrivers 16■■ Torx 17■■ Pliers 19■■ Basic Hand Tool List 22■■ Tool Sets and Accessories 23■■ Electrical Hand Tools 23■■ Hand Tool Maintenance 25■■ Trouble Lights 25■■ Air and Electrically Operated Tools 25■■ Personal Protective Equipment 27■■ Safety Precautions 28■■ Vehicle Protection 29■■ Safety Lifting (Hoisting) a Vehicle 29■■ Jacks and Safety Stands 31■■ Drive-On Ramps 31■■ Electrical Cord Safety 32■■ Jump Starting and Battery Safety 32
■■ Fire Extinguishers 33■■ Fire Blankets 34■■ First Aid and Eye Wash Stations 34■■ Hybrid Electric Vehicle Safety Issues 35
Summary 40review QueStionS 40Chapter Quiz 40
chapter 3
ENVIRONMENTAL AND HAZARDOUS MATERIALS 42
■■ Learning Objectives 42■■ Key Terms 42■■ Hazardous Waste 42■■ Federal and State Laws 42■■ Asbestos Hazards 44■■ Used Brake Fluid 45■■ Used Oil 45■■ Solvents 46■■ Coolant Disposal 47■■ Lead-Acid Battery Waste 48■■ Fuel Safety and Storage 48■■ Airbag Handling 49■■ Used Tire Disposal 49■■ Air-Conditioning Refrigerant Oil Disposal 50
Summary 52review QueStionS 52Chapter Quiz 52
chapter 4
TIRES AND WHEELS 53■■ Learning Objectives 53■■ Key Terms 53■■ Introduction to Tires 53■■ Parts of a Tire 53■■ Tire Molding 56■■ Service Description 58■■ High-Flotation Tire Sizes 58■■ Load Index and Equivalent Loads 59■■ Speed Ratings 59■■ Tire Pressure and Traction 60■■ Rim Width and Tire Size 60■■ Uniform Tire Quality Grading System 61■■ All-Season Tire Designation 63
iv
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■■ Types of Tires 63■■ DOT Tire Code 63■■ Tire Conicity and Ply Steer 64■■ Vehicle Handling and Tire Slip Angle 65■■ Spare Tires 65■■ Run-Flat Tires 66■■ General Motors TPC Rating 67■■ Tire Selection Considerations 68■■ Noise-Reducing Tires 69■■ Wheels 69■■ Tire Valves 72■■ Unsprung Weight 73■■ Lug Nuts 73
Summary 77review QueStionS 77Chapter Quiz 77
chapter 5
TIRE-PRESSURE MONITORING SYSTEMS 78
■■ Learning Objectives 78■■ Key Terms 78■■ Need for Tire Pressure Monitoring 78
■■ Tread Act 80■■ Indirect TPMS 80■■ Direct TPMS 81■■ TPMS Pressure Sensors 82■■ TPMS Sensor Operation 83■■ TPMS Receiver 84■■ TPMS Diagnosis 85■■ TPMS Sensor Activations 86■■ TPMS Diagnostic Tools 86■■ Sensor Replacement Options 87■■ TPMS Sensor Relearn 88■■ TPMS Sensor Service Tools 89
Summary 90review QueStionS 91Chapter Quiz 91
chapter 6
TIRE AND WHEEL SERVICE 92■■ Learning Objectives 92■■ Key Terms 92■■ Tire Service and Proper Inflation 92■■ Nitrogen Inflation 93■■ Tire Inspection 94■■ Wheel Removal/Installation 95■■ Tire Rotation 97■■ Radial Runout 98■■ Lateral Runout 99
■■ Tire Replacement 100■■ Tire Balancing 103■■ Wheel Weights 103■■ Wheel/Tire Balancers 106■■ Tire Repair 107
Summary 115review QueStionS 115Chapter Quiz 115
chapter 7
SUSPENSION SYSTEM COMPONENTS AND OPERATION 117
■■ Learning Objectives 117■■ Key Terms 117■■ Introduction 117■■ Frame Construction 117■■ Platforms 119■■ Unsprung Weight 119■■ Types of Suspensions 119■■ Hooke’s Law 120■■ Coil Springs 120■■ Leaf Springs 124■■ Torsion Bars 127■■ Suspension Principles 127■■ Steering Knuckles 129■■ Control Arms 130■■ Ball Joints 130■■ Strut Rods 131■■ Stabilizer Bars 133■■ Shock Absorbers 133■■ Struts 136■■ Bump Stops 136
Summary 141review QueStionS 141Chapter Quiz 141
chapter 8
FRONT SUSPENSION AND SERVICE 142
■■ Learning Objectives 142■■ Key Terms 142■■ Front Suspension Types 142■■ Short-/Long-Arm Suspensions 143■■ Strut Suspension 145■■ Servicing the Suspension System 146
■■ Road Test Diagnosis 146■■ Dry Park Test (Suspension) 148■■ Visual Inspection 149
CONTENTS v
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■■ Ball Joints 150■■ Kingpin Diagnosis and Service 156■■ Shock Absorbers and Struts 156■■ MacPherson Strut Replacement 158■■ Stabilizer Bar Links and Bushings 160■■ Strut Rod Bushings 160■■ Front Coil Springs 161■■ Steering Knuckles 163■■ Torsion Bars 164■■ Control Arm Bushings 164
Summary 170review QueStionS 170Chapter Quiz 170
chapter 9
REAR SUSPENSION AND SERVICE 172
■■ Learning Objectives 172■■ Key Terms 172■■ Solid Rear Axles 172■■ Leaf Spring Rear Suspensions 173■■ Trailing Arm Rear Suspensions 174■■ Semi-Trailing Arm Rear Suspensions 175■■ Independent Rear Suspensions 175■■ Semi-Independent Rear Suspensions 176■■ Rear Suspension Service 176■■ Rear Shock Replacement 177■■ Rear Spring Replacement 179
Summary 182review QueStionS 182Chapter Quiz 182
chapter 10
ELECTRONIC SUSPENSION SYSTEMS 184
■■ Learning Objectives 184■■ Key Terms 184■■ The Need for Electronic Suspensions 184■■ Electronic Suspension Controls and Sensors 184
■■ Electronic Suspension System Actuators 190
■■ Types of Electronic Suspension 192■■ Automatic Level Control (ALC) 196■■ Troubleshooting Rear Electronic Leveling Systems 198
■■ Magneto-Rheological (MR) Suspension 198
Summary 200review QueStionS 200Chapter Quiz 200
chapter 11
ELECTRONIC STABILITY CONTROL SYSTEMS 201
■■ Learning Objectives 201■■ Key Terms 201■■ The Need for Electronic Stability Control 201
■■ Federal Motor Vehicle Safety Standard (FMVSS) No. 126 202
■■ Sine with Dwell Test 202■■ ESC Sensors 204■■ Traction Control 205■■ ESC/TC Diagnosis 208
Summary 208review QueStionS 209Chapter Quiz 209
chapter 12
STEERING COLUMNS AND GEARS 210
■■ Learning Objectives 210■■ Key Terms 210■■ Steering Wheels 210■■ Steering Wheel Removal 211■■ Steering Columns 212■■ Conventional Steering Gears 216■■ Recirculating Ball Steering Gear 219
■■ Steering Gear Adjustments 220■■ Rack-and-Pinion Steering Gear 222■■ Rack-and-Pinion Adjustments 225
Summary 226review QueStionS 226Chapter Quiz 226
chapter 13
STEERING LINKAGE AND SERVICE 228
■■ Learning Objectives 228■■ Key Terms 228■■ Steering Linkage 228■■ Rack-and-Pinion Inner Tie Rod Ends 229■■ Front Steer Versus Rear Steer 231■■ Four-Wheel Steering Systems 232■■ Steering Linkage Lubrication 233■■ Dry Park Test 234■■ Common Wear Items 236■■ Under-Vehicle Inspection 236■■ Steering Linkage Replacement 238
vi CONTENTS
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Summary 245review QueStionS 245Chapter Quiz 245
chapter 14
HYDRAULIC POWER STEERING SYSTEMS 246
■■ Learning Objectives 246■■ Key Terms 246■■ Hydraulic Power Steering Systems 246■■ Power Steering Pump and Reservoir 247■■ Integral Power Steering 250■■ Variable-Effort Steering 254■■ Power Steering Diagnosis 259■■ Power Steering Fluid 260
Summary 269review QueStionS 269Chapter Quiz 269
chapter 15
ELECTRIC POWER STEERING SYSTEMS 271
■■ Learning Objectives 271■■ Key Terms 271■■ Electric Power Steering Overview 271■■ EPS System Parts and Operation 272■■ Steering Shaft Torque Sensor 275■■ Steering Wheel Position Sensor 275■■ Power Steering Motor 275■■ Power Steering Control Module (PSCM) 275■■ EPS Diagnosis 276■■ Self-Parking System 276■■ Electrohydraulic Power Steering 277
Summary 278review QueStionS 278Chapter Quiz 278
chapter 16
WHEEL BEARINGS AND SERVICE 280
■■ Learning Objectives 280■■ Key Terms 280■■ Antifriction Bearings 280■■ Bearing Greases 283■■ Seals 284■■ Bearing Diagnosis 284■■ Wheel Bearing Service 285■■ Sealed Bearing Replacement 289■■ Rear Drive Axle Classifications 289
■■ Rear Axle Bearing and Seal Replacement 290■■ Bearing Failure Analysis 292
Summary 297review QueStionS 297Chapter Quiz 297
chapter 17
DRIVESHAFTS AND CV JOINTS 299
■■ Learning Objectives 299■■ Key Terms 299■■ DriveShafts 299■■ Driveshaft Balance 299■■ U-Joint Design and Operation 300■■ Double-Cardan Joints 303■■ Constant Velocity Joints 303
Summary 308review QueStionS 308Chapter Quiz 308
chapter 18
DRIVESHAFT AND CV JOINT SERVICE 310
■■ Learning Objectives 310■■ Key Terms 310■■ U-Joint Diagnosis 310■■ Driveshaft and U-Joint Inspection 311■■ U-Joint Replacement 312■■ U-Joint Working Angles 314■■ CV Joint Diagnosis 315■■ Replacement Shaft Assemblies 315■■ CV Joint Service 316
Summary 323review QueStionS 323Chapter Quiz 323
chapter 19
WHEEL ALIGNMENT PRINCIPLES 324
■■ Learning Objectives 324■■ Key Terms 324■■ Definition of a Wheel Alignment 324■■ Alignment-Related Problems 324■■ Camber 325■■ Caster 327■■ Toe 330■■ Steering Axis Inclination 333■■ Included Angle 334
CONTENTS vii
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■■ Scrub Radius 334■■ Turning Radius (Toe-Out on Turns) 336■■ Setback 337■■ Thrust Angle 337■■ Tracking 338■■ Four-Wheel Alignment 338
Summary 339review QueStionS 339Chapter Quiz 339
chapter 20
ALIGNMENT DIAGNOSIS AND SERVICE 340
■■ Learning Objectives 340■■ Key Terms 340■■ Purpose of an Alignment 340■■ Prealignment Correction Techniques 340■■ Prealignment Checks 340■■ Lead/Pull 342■■ Memory Steer 343■■ Torque Steer 343■■ Alignment Specifications 345■■ Alignment Setup Procedures 346■■ Measuring Camber, Caster, SAI, Toe, and TOOT 347
■■ Specifications Versus Alignment Readings 348■■ Checking for Bent Struts, Spindles, or Control Arms 348
■■ Checking Frame Alignment of Front-Wheel-Drive Vehicles 349
■■ Types of Alignments 350■■ Adjusting Rear Camber 353■■ Guidelines for Adjusting Front Camber/SAI and Included Angle 354
■■ Front Camber/Caster Adjustment Methods 355
■■ Adjusting Front Camber/Caster 356■■ Setting Toe 356■■ Centering the Steering Wheel 358■■ Tolerance Adjustment Procedure 359■■ Aligning Electronic-Suspension Vehicles 360■■ Aligning Modified Vehicles 361
■■ Hidden Structural Damage Diagnosis 364■■ Reset Steering Angle Sensor (SAS) 364
Summary 370review QueStionS 370Chapter Quiz 370
chapter 21
VIBRATION AND NOISE DIAGNOSIS AND CORRECTION 372
■■ Learning Objectives 372■■ Key Terms 372■■ Causes of Vibration and Noise 372■■ Test-Drive 373■■ Neutral Run-Up Test 375■■ Vibration During Braking 375■■ Vibration Speed Ranges 375■■ Vibration Frequency 378■■ Correcting Driveline Angles 380■■ Checking Driveshaft Runout 380■■ Measuring Driveshaft U-Joint Phasing 380■■ Checking Companion Flange Runout 380■■ Balancing the Driveshaft 381■■ Noise Diagnosis 381■■ Noise Correction 382
Summary 385review QueStionS 385Chapter Quiz 385
appendix 1 SAMPLE SUSPENSION AND STEERING (A4) ASE-TYPE CERTIFICATION TEST 386
appendix 2 2017 ASE CORRELATION CHART 390
GLOSSARY 394
INDEX 404
viii CONTENTS
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ix
PREFACEPROFESSIONAL TECHNICIAN SERIES Part of Pearson Automotive’s Series, the eighth edition of Automotive Steering, Suspension, and Alignment represents the future of automotive textbooks. The series is a full-color, media-integrated solution for today’s students and instructors. The series includes textbooks that cover all eight areas of ASE certification, plus additional titles covering common courses.
The series is also peer reviewed for technical accuracy.
NEW THIS EDITION Based on the suggestions and rec-ommendations from automotive instructors and reviewers, the following changes have been made to the eighth edition:
■" The number of chapters have been increased from 20 to 21 to help meet the latest ASE tasks. The new chapter is Chapter 3 – Service Information, Work Orders and Vehicle Identification.
■" Over 40 new full-color photos and line drawings to make the subject come alive.
■" Updated throughout and correlated to the latest ASE A4 tasks.
■" New Case Studies included in this edition covering the “three Cs” (Complaint, Cause, and Correction).
■" New OSHA hazardous chemical labeling requirements added to Chapter 2.
■" Additional content on snap-in and clamp-on TPMS sensors, plus updated relearn procedures, in chapter 5.
ASE CORRELATED This comprehensive textbook is divid-ed into sections that correspond to the A4 area of certifications as specified by the National Institute for Automotive Service Excellence (ASE). The areas of the ASE material certification test are listed in the objectives at the beginning of each chap-ter, and all laboratory worksheets are correlated to the ASE Task Sheets.
A COMPLETE INSTRUCTOR AND STUDENT SUPPLE-MENTS PACKAGE All Professional Technician textbooks are accompanied by a full set of instructor and student supple-ments. Please see page xii for a detailed list of supplements.
A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING The Professional Technician Series has been developed to satisfy the need for a greater emphasis on problem diag-nosis. Automotive instructors and service managers agree that students and beginning technicians need more training in diagnostic procedures and skill development. To meet this need and demonstrate how real-world problems are solved, “Case Study” features are included throughout and highlight how real-life problems are diagnosed and re-paired.
The following pages highlight the unique core features that set the Pearson Automotive Series book apart from other automotive textbooks.
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x IN-TEXT FEATURES
SAFETY TIPS alert students to possible hazards on the job and how to avoid them.
IN-TEXT FEATURES
Shop Cloth Disposal
Always dispose of oily shop cloths in an enclosed container to prevent a fire. ● SEE FIGURE 2–63. Whenever oily cloths are thrown together on the floor or workbench, a chemical reaction can occur, which can ignite the cloth even without an open flame. This process of ignition without an open flame is called spontaneous combustion.
SAFETY TIP
The Rattle Story
A customer complained that a rattle was heard every time the vehicle hit a bump. The noise sounded as if it came from the rear. All parts of the exhaust system and suspension system were checked. Everything seemed okay until the vehicle was raised with a frame-type hoist instead of a drive-on type. Then, whenever the right rear wheel was lifted, the noise occurred. The problem was a worn (elongated) shock absorber mounting hole. A washer with the proper-size hole was welded over the worn lower frame mount and the shock absorber was bolted back into place.
Summary:■■ Complaint—Vehicle owner complained of a rattle
sound from the rear suspension at times.■■ Cause—The lower shock mount was found to be
worn (elongated) causing the noise.■■ Correction—A steel washer was welded over the
worn lower frame mount which restored the shock mount to the correct size and solved the noise issue.
CASE STUDY
CASE STUDIES present students with actual automotive scenarios and shows how these common (and sometimes uncommon) problems were diagnosed and repaired.
It Just Takes a Second
Whenever removing any automotive component, it is wise to screw the bolts back into the holes a couple of threads by hand. This ensures that the right bolt will be used in its original location when the compo-nent or part is put back on the vehicle.
TECH TIP
TECH TIPS feature real-world advice and “tricks of the trade” from ASE-certified master technicians.
LEARNING OBJECTIVES AND KEY TERMS appear at the beginning of each chapter to help students and instruc-tors focus on the most important material in each chapter. The chapter objectives are based on specific ASE and NATEF tasks.
SERVICE INFORMATION, WORK ORDERS, AND VEHICLE IDENTIFICATION 1
SERVICE INFORMATION, WORK ORDERS, AND VEHICLE IDENTIFICATION1
chapter
LEARNING OBJECTIVES:After studying this chapter, the reader should be able to:Discuss the importance of vehicle owner’s manuals, service records, and service information.Explain the different types of service information.Describe vehicle recalls and campaigns.Discuss the importance of the work order.Explain why service records are important.Discuss the parts of a vehicle, and differentiate between front-wheel drive and rear-wheel drive.
Explain vehicle identification, vehicle safety certification label, and the VECI label.Discuss the different types of emission standards.Explain calibration codes and casting numbers.
This chapter will help prepare for the Suspension and Steering (A4) and Brakes (A5) ASE certification test.
KEY TERMS: Campaign 2 • Country of origin 6 • Flat rate 3 • Gross axle weight rating (GAWR) 7 • Gross vehicle weight rating (GVWR) 7 • Model year (MY) 6 • Owner’s manual 1 • Recall 2 • Repair order (RO) 3 • Service information 2 • Technical service bulletin (TSB) 2 • Vehicle emissions control information (VECI) 7 • Vehicle identification number (VIN) 6 • Work order 3
FIGURE 1–1 The owner’s manual has a lot of information pertaining to the operation, as well as the maintenance and resetting procedures, that technicians often need.
CONTENT The owner’s manual is the instructional booklet that comes with every new vehicle and includes important in-formation. It has been said by many automotive professional technicians and service advisors that the owner’s manual is not read by many vehicle owners. Most owners’ manuals contain all or most of the following information.
1. Meaning of dash symbols
2. How to reset the maintenance reminder light
3. Specifications, including viscosity of oil needed and num-ber of quarts (liters)
4. Tire pressures and standard, as well as optional, tire sizes
5. Maintenance schedule for all fluids, including coolant, brake fluid, automatic transmission fluid, and differential fluid
6. How to program the remote control, as well as the power windows and door locks
7. How to reset the tire pressure monitoring system (TPMS) after a tire rotation SEE FIGURE 1–1.
OWNER’S MANUALS
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IN-TEXT FEATURES xi
How Many Types of Screw Heads Are Used in Automotive Applications?
There are many, including Torx, hex (also called Allen), plus many others used in custom vans and motor homes. ● SEE FIGURE 1–9.
FREQUENTLY ASKED QUESTION
FREQUENTLY ASKED QUESTIONS are based on the author’s own experience and provide answers to many of the most common questions asked by students and beginning ser-vice technicians.
?
NOTES provide students with additional technical informa-tion to give them a greater understanding of a specific task or procedure.
NOTE: Most of these “locking nuts” are grouped together and are commonly referred to as prevail-ing torque nuts. This means that the nut will hold its tightness or torque and not loosen with movement or vibration.
CAUTIONS alert students about potential damage to the vehicle that can occur during a specific task or service procedure.
CAUTION: Never use hardware store (nongraded) bolts, studs, or nuts on any vehicle steering, suspen-sion, or brake component. Always use the exact size and grade of hardware that is specified and used by the vehicle manufacturer.
Do not use incandescent trouble lights around gasoline or other flammable liquids. The liquids can cause the bulb to break and the hot filament can ignite the flammable liquid which can cause personal injury or even death.
WARNING
WARNINGS alert students to potential dangers to them-selves during a specific task or service procedure.
40 CHAPTER 2
1. Bolts, studs, and nuts are commonly used as fasteners in the chassis. The sizes for fractional and metric threads are different and are not interchangeable. The grade is the rating of the strength of a fastener.
2. Whenever a vehicle is raised above the ground, it must be supported at a substantial section of the body or frame.
3. Wrenches are available in open end, box end, and combi-nation open and box end.
4. An adjustable wrench should only be used where the proper size is not available.
5. Line wrenches are also called flare-nut wrenches, fitting wrenches, or tube-nut wrenches and are used to remove fuel or refrigerant lines.
6. Sockets are rotated by a ratchet or breaker bar, also called a flex handle.
SUMMARY
7. Torque wrenches measure the amount of torque applied to a fastener.
8. Screwdriver types include straight blade (flat tip) and Phillips.
9. Hammers and mallets come in a variety of sizes and weights.
10. Pliers are a useful tool and are available in many different types, including slip-joint, multigroove, linesman’s, diago-nal, needle-nose, and locking pliers.
11. Other common hand tools include snap-ring pliers, files, cutters, punches, chisels, and hacksaws.
12. Hybrid electric vehicles should be de-powered if any of the high-voltage components are going to be serviced.
REVIEW QUESTIONS
1. Why are wrenches offset 15 degrees?
2. What are the other names for a line wrench?
3. What are the standard automotive drive sizes for sockets?
4. Which type of screwdriver requires the use of a hammer or mallet?
5. What is inside a dead-blow hammer?
CHAPTER QUIZ
1. The correct location for the pads when hoisting or jacking the vehicle can often be found in the ______________.a. service manualb. shop manual
c. owner’s manuald. all of the above
2. For the best working position, the work should be ______________.a. at neck or head levelb. at knee or ankle levelc. overhead by about 1 footd. at chest or elbow level
3. A high-strength bolt is identified by ______________.a. a UNC symbolb. lines on the headc. strength letter codesd. the coarse threads
4. A fastener that uses threads on both ends is called a ______________.a. cap screwb. stud
c. machine screwd. crest fastener
5. Wrenches are made from _______.a. cast from nickel steelb. forged alloy steelc. machined from billet steeld. cast from chrome steel
6. The proper term for Channel Locks is ______________.a. Vise Gripsb. crescent wrenchc. locking pliersd. multigroove adjustable pliers
7. The proper term for Vise Grips is ______________.a. locking pliersb. slip-joint pliersc. side cutsd. multigroove adjustable pliers
THE SUMMARY, REVIEW QUESTIONS, AND CHAPTER QUIZ at the end of each chapter help students review the material presented in the chapter and test themselves to see how much they’ve learned.
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xii SUPPLEMENTS
38 CHAPTER 2 TOOLS AND SAFETY 39
STEP BY STEPHOISTING THE VEHICLE
The first step in hoisting a vehicle is to properly align the vehicle in the center of the stall.1
3 The arms can be moved in and out and most pads can be rotated to allow for many different types of vehicle construction.
5 Tall pad extensions can also be used to gain access to the frame of a vehicle. This position is needed to safely hoist many pickup trucks, vans, and sport util-ity vehicles.
Most lifts are equipped with short pad extensions that are often necessary to use to allow the pad to contact the frame of a vehicle without causing the arm of the lift to hit and damage parts of the body.
4
An additional extension may be necessary to hoist a truck or van equipped with running boards to give the necessary clearance.6
Position the pads under the vehicle under the recommended locations.7 After being sure all pads are correctly positioned,
use the electromechanical controls to raise the vehicle.8
With the vehicle raised 1 foot (30 cm) off the ground, push down on the vehicle to check to see if it is stable on the pads. If the vehicle rocks, lower the vehicle and reset the pads. The vehicle can be raised to any desired working level. Be sure the safety is engaged before working on or under the vehicle.
9 If raising a vehicle without a frame, place the flat pads under the pinch weld seam to spread the load. If additional clearance is necessary, the pads can be raised as shown.
10
When the service work is completed, the hoist should be raised slightly and the safety released before using the hydraulic lever to lower the vehicle.
11 After lowering the vehicle, be sure all arms of the lift are moved out of the way before driving the vehicle out of the work stall.12
Most vehicles will be correctly positioned when the left front tire is centered on the tire pad.2
STEP-BY-STEP photo sequences show in detail the steps involved in performing a specific task or service procedure.
SUPPLEMENTS
RESOURCES IN PRINT AND ONLINEAutomotive Steering, Suspension, and Alignment
NAME OF SUPPLEMENT PRINT ONLINE AUDIENCE DESCRIPTION
Instructor Resource Manual 0135674581
✔ Instructors NEW! The ultimate teaching aid: chapter summaries, key terms, chapter learning objectives, and lecture resources
TestGen 0135674530
✔ Instructors Test generation software and test bank for the text.
PowerPoint Presentation 013575836X
✔ Instructors Slides include chapter learning objectives, lecture outline of the text, and graphics from the book.
Image Bank 0135758424
✔ Instructors All of the images and graphs from the textbook to create customized lecture slides.
ASE Correlated Task Sheets – for Instructors 0135674638
✔ Instructors Downloadable ASE task sheets for easy customization and development of unique task sheets.
ASE Correlated Task Sheets – For Students 0135758416
✔ Students Study activity manual that correlates ASE Automobile Standards to chapters and page numbers in the text. Available to students at a discounted price when packaged with the text.
VitalSource eBook 0135674581
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All online resources can be downloaded from the Instructor’s Resource Center: www.pearsonhighered.com Search for your specific title there and select the Resources.
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ACKNOWLEDGMENTS xiii
Tony MartinUniversity of Alaska Southeast
Kerry MeierSan Juan College
Jim MortonAutomotive Training Center (ATC)
Fritz PeacockIndiana Vocational Technical College
Dennis PeterNAIT (Canada)
Greg PfahlMiami-Jacobs Career College
Steve PolleyPittsburgh State University
Kenneth RedickHudson Valley Community College
Jeff RehkopfFlorida State College
Mark SpisakCentral Piedmont Community College
Chuck TaylorSinclair Community College
Walter VarellaTrident Technical College
Mitchell WalkerSt. Louis Community College at Forest Park
Jennifer WiseSinclair Community College
Special thanks to instructional designerAlexis Skriloff James.
PHOTO SEQUENCES The author wishes to thank Brad Halderman, Alyssa Williams, Carl Borsani, plus Chuck Taylor of Sinclair Community College in Dayton, Ohio, plus Steve Cartwright who helped with many of the photos. Special thanks to Dick Krieger and Jeff Rehkopf for their detailed and thorough review of the manuscript before publication and to Richard Reaves for all of his help.
Most of all, I wish to thank Michelle Halderman for her assistance in all phases of manuscript preparation.
—James D. Halderman
A large number of people and organizations have cooperated in providing the reference material and technical information used in this text. The author wishes to express sincere thanks to the fol-lowing individuals and organizations for their special contributions:
Steve Cartwright—Federal-MogulBrad Halderman—Hankook TiresJoe Palazzolo—GKN DrivelineDave Fox—Hunter EngineeringCarl Borsani—Graphic Home
TECHNICAL AND CONTENT REVIEWERS The following people reviewed the manuscript before production and checked it for technical accuracy and clarity of presentation. Their sug-gestions and recommendations were included in the final draft of the manuscript. Their input helped make this textbook clear and technically accurate while maintaining the easy-to-read style that has made other books from the same author so popular.
Jim AndersonGreenville High School
Victor BridgesUmpqua Community College
Dr. Roger DonovanIllinois Central College
A. C. DurdinMoraine Park Technical College
Al EngledahlCollege of Dupage
Orlando GrijalvaTarrant County College, South
Larry HagelbergerUpper Valley Joint Vocational School
Oldrick HajzlerRed River College
Betsy HoffmanVermont Technical College
Richard KriegerMichigan Institute of Technology
Steven T. LeeLincoln Technical Institute
Carlton H. Mabe, Sr.Virginia Western Community College
Roy MarksOwens Community College
ACKNOWLEDGMENTS
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xiv ABOUT THE AUTHOR
JIM HALDERMAN brings a world of experience, knowledge, and talent to his work. His automotive service experience in-cludes working as a flat-rate technician, a business owner, and a professor of automotive technology at a leading U.S. com-munity college for more than 20 years.
He has a Bachelor of Science Degree from Ohio North-ern University and a Master’s Degree in Education from Miami University in Oxford, Ohio. Jim also holds a U.S. Patent for an electronic transmission control device. He is an ASE-certified Master Automotive Technician and Advanced Engine Perfor-mance (L1) ASE-certified.
Jim is the author of many automotive textbooks all pub-lished by Pearson Education.
Jim has presented numerous technical seminars to na-tional audiences including the California Automotive Teachers (CAT) and the Illinois College Automotive Instructor Association (ICAIA). He is also a member and presenter at the North Ameri-can Council of Automotive Teachers (NACAT). Jim was also named Regional Teacher of the Year by General Motors Cor-poration and a member of the advisory broad for Technological Studies department at Ohio Northern University.
Jim and his wife, Michelle, live in Dayton, Ohio. They have two children. You can reach Jim at
ABOUT THE AUTHOR
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