33S15T0 steering and suspendion diagnosis 2007

It is conducted with exercises in steering and suspensiondiagnosis, and will cover: – Steering and/or suspension system diagnosis – Diagnostic tool usage – Service publication usage In o

Steering and Suspension Diagnosis

IMPORTANT SAFETY NOTICE

Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles,

as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability.

There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts.

As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful

in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle.

• Always wear safety glasses for eye protection.

• Use safety stands whenever a procedure requires you to

be under the vehicle.

• Be sure that the ignition switch is always in the OFF

position, unless otherwise required by the procedure.

• Set the parking brake when working on the vehicle If you

have an automatic transmission, set it in PARK unless

instructed otherwise for a specific service operation If

you have a manual transmission it should be in

RE-VERSE (engine OFF) or NEUTRAL (engine ON) unless

instructed otherwise for a specific service operation.

• Operate the engine only in a well-ventilated area to avoid

the danger of carbon monoxide.

• Keep yourself and your clothing away from moving parts

when the engine is running, especially the fan and belts.

• To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler.

• Do not smoke while working on the vehicle.

• To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head.

• Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood.

The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions do not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern.

The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual

is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice.

WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing

the asbestos dust can cause asbestosis and cancer.

Breathing asbestos dust is harmful to your health.

Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing.

Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag.

If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators.

OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area.

Technical Service Support Operations

Customer Expectations: Service

1. Make it convenient to have my vehicle

serviced at your dealership.

2. The Service Advisor should demonstrate

a genuine concern for my service needs.

3. Fix it right the first time, on time.

4. Complete servicing my vehicle in a

timely and professional manner.

5. Provide me with a clear and thorough explanation of the service performed.

6. Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied.

7. Be responsive to questions or concerns that I bring to your attention.

Expectation #3

“Fix It Right the First Time, on Time.”

Both service advisors and technicians are important players when it comes to Expectation #3.

Why

Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced.

Technician Training

It is our goal to help the technician acquire all of the skills and knowledge necessary to

“Fix it Right the First Time, on Time.” We refer to this as “competency.”

— Repeat vehicle sales

— Repeat service sales

— Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business”

STEERING AND SUSPENSION DIAGNOSIS TABLE OF CONTENTS

INTRODUCTION INTRO - 1

Steering and Suspension Diagnosis Intro - 2Course description Intro - 2Worksheets Intro - 2Course requirements Intro - 3Course objectives Intro - 3

PREREQUISITE REVIEW 1 - 2

LESSON ONE WORKSTATIONS 1 - 13

Lesson One – Workstation 1: Purging the powersteering system 1 - 14Lesson One – Workstation 2: Power steering diagnosis using CMT 1 - 16Lesson One – Workstation 3: Balljoint inspection 1 - 18Lesson One – Workstation 4: Suspension inspection 1 - 21

INSTRUCTOR-LED DEMONSTRATION: RIDE HEIGHT CALIBRATION 2 - 1

LESSON TWO WORKSTATIONS 2 - 3

Lesson Two – Workstation 1: Rear air suspension diagnosis 2 - 4Lesson Two – Workstation 2: Alignment concern using CMT 2 - 5Lesson Two – Workstation 3: Air suspension diagnosis 2 - 12Lesson Two – Workstation 4: Component testing 2 - 14

LESSON THREE WORKSTATIONS 3 - 1

Lesson Three – Workstation 1: Steering system diagnosis 3 - 2Lesson Three – Workstation 2: Alignment concern using CMT 3 - 3Lesson Three – Workstation 3: Air suspension diagnosis 3 - 8Lesson Three – Workstation 4: Rear suspension concern 3 - 9

APPENDIX APPENDIX - 1

Balljoint Job Aid APPENDIX - 3

STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION

INTRODUCTION

This is a 3-day course facilitated by an instructor This course is designed to provide hands-on

opportunities for you to learn and improve your skills using tools and equipment and to apply knowledgelearned in previous curriculum courses Each day you will have multiple opportunities to practice selectedskills The results of your work are recorded on worksheets

Worksheets

All classroom and hands-on activities are guided by worksheets When you are assigned to one of fourworkstations, you will be given 30 to 45 minutes to complete the tasks and questions required by the worksheet forthat workstation Every 30 to 45 minutes, you will move to another workstation and complete another worksheetuntil all four worksheets are complete

Steering and Suspension Diagnosis

Course Description

STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION

Course Requirements

Each technician attending this course is required to pass a combination of hands-on and written

evaluations These are administered on the afternoon of the fourth day

z The hands-on evaluation is a pass/fail type It is conducted with exercises in steering and suspensiondiagnosis, and will cover:

– Steering and/or suspension system diagnosis

– Diagnostic tool usage

– Service publication usage

In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-onexercise AND you must answer at least 80% of the written post-test questions correctly

Course Objectives

Upon successful completion of this course, you will be able to:

z Properly inspect and test steering and suspension system components

z Correctly inspect ball joints and measure ball joint deflection

z Correctly fill a power steering system after component replacement

z Correctly purge air from the power steering system

z Perform a simulated pump flow and pressure test using a power steering analyzer

z Diagnose and correct excessive tire wear and pull concerns using a simulated alignment machine

LESSON ONE PREREQUISITE REVIEW

LESSON ONE

1 Identify the steering system components below:

A. B. C. D.

2 The power steering analyzer can help diagnose:

A Internal leakage in the steering gear

B Malfunctions in the power steering pump

C Blocked or crimped hoses

D All of the above

PREREQUISITE REVIEW

DIRECTIONS: Answer the following questions These will be reviewed in class.

LESSON ONE PREREQUISITE REVIEW

3 A customer brings in a vehicle for a hard steering effort concern Based on the test results below, what is thelikely cause of the concern?

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4 Which of the following best describes the VAPS system?

A Provides varying levels of assist depending on temperature

B Provides varying levels of assist depending on vehicle speed

C Provides varying levels of assist depending on steering rate only

D Provides varying levels of assist depending on engine RPM

5 Which component controls the amount of fluid flow to the hydraulic rotary valve in the steering gear

in a VAPS system?

A Control valve actuator

B Steering wheel rotation sensor

C Powertrain control module

D Vehicle speed sensor

6 If the VAPS actuator is de-energized, the power steering system will provide:

A Minimum assist

B Maximum assist

C Variable assist

D No assist

LESSON ONE PREREQUISITE REVIEW

7 Identify the components in the suspension system below:

9 Using the graphic above, identify which component(s) prevent longitudinal movement of the axle.

10 Using the graphic above explain what the stabilizer bar does

11 Identify the suspension system components below:

13 Using the graphic above, identify which component(s) prevent longitudinal movement of the axle.

14 Using the graphic above explain what the stabilizer bar does

LESSON ONE PREREQUISITE REVIEW

15 Which of the components below would be considered unsprung weight? Circle all that apply

16 Ride height is a measurement from a(n):

A Unsprung suspension component to a sprung component

B Unsprung suspension component to the ground

C Sprung suspension component to the ground

D Sprung suspension component to the wheel center

17 Briefly explain the purpose of an air suspension system

18 Before raising a vehicle equipped with air suspension on a hoist, you should:

19 Number the following alignment steps in the proper order that they should be performed

Install the brake pedal depressor _

Center the steering wheel _

Mount the alignment heads to the wheel _

Perform a run out compensation _

Perform a caster swing _

20 Number the following alignment angles in the proper order in which they are adjusted

Front camber/caster

Front toe

Rear camber

Rear toe

21 Why is the rear axle adjusted before the front axle?

22 Why is camber and caster adjusted before toe?

23 Identify the alignment angles adjusted at the points shown in the graphic below

A. B. C.

24 Identify which alignment angle(s) may contribute to the symptom of a pulling concern Circle all thatapply

LESSON ONE PREREQUISITE REVIEW

25 What non-alignment related systems or components could cause a vehicle to pull?

26 What symptom would be associated with the alignment readings below? Circle all that apply

A Vehicle pulls to one side

B Steering wheel is not straight

C Tire wear

D No noticeable concern

27 What symptom would be associated with the alignment readings below? Circle all that apply

A Vehicle pulls to one side

B Steering wheel is not straight

C Tire wear

D No noticeable concern

28 What symptom would be associated with the alignment readings below? Circle all that apply.

A Vehicle pulls to one side

B Steering wheel is not straight

LESSON ONE PREREQUISITE REVIEW

30 Identify the angles in the graphic below

A. B. C.

31 Steering axis inclination and included angle are most commonly used to identify

LESSON ONE WORKSTATIONS

LESSON ONE WORKSTATIONS

No Task Summary

1 In this activity you will induce and purge air from the power steering system and use the power

steering fill adapter manifold to fill the system

2 In this activity you will complete a computer based scenario This workstation contains one scenario

3 In this activity you will use the workshop manual to visually inspect the workstation vehicle

4 In this activity you will use the workshop manual to answer suspension and alignment-related questions

WORKSTATION 1 PURGING THE POWER STEERING SYSTEM

DIRECTIONS: Complete Workstation 1 at a vehicle workstation.

SUMMARY: In this activity you will induce and purge air from the power steering system and use the

power steering fill adapter manifold to fill the system

Part 1 - Power Steering System Purging

Induce Air in the Power Steering System.

z Empty the power steering reservoir using the vacuum pump and a suitable reservoir

1 How much fluid was removed from the reservoir?

_

z Start the vehicle

z Turn the steering wheel lock-to-lock

z Turn the engine OFF

z Empty the power steering reservoir again using the vacuum pump and a suitable reservoir

2 How much fluid was removed from the reservoir?

_

LESSON ONE WORKSTATION 1

z Add fluid to the reservoir up to the max level

z Start the vehicle and note the fluid level

z Turn OFF the vehicle and note the fluid level

3 Does the fluid level raise or lower when the vehicle is started

a Raise

b Lower

c Stay the same

Purge the air from the Power Steering System.

z Refer to the Power Steering System Purging procedure in the workshop manual

4 Do the front wheels need to be raised during this procedure?

5 How much vacuum is applied during this procedure?

6 How many times should the steering wheel be turned lock-to-lock?

z Perform the procedure to purge the air from the system

Part 2 - Power Steering System Filling

Remove the fluid from the Power Steering System.

z Empty the power steering reservoir using the vacuum pump and a suitable reservoir

7 How much fluid was removed from the reservoir?

_

z Start the vehicle

z Turn the steering wheel lock-to-lock

z Turn the engine OFF

8 How much fluid was removed from the reservoir?

_

z Start the vehicle

z Turn the steering wheel lock-to-lock

z Turn the engine OFF

Fill the Power Steering System using the fill adapter manifold.

z Perform the Power Steering System filling procedure in the workshop manual

9 Did the procedure fill the system with the same amount of fluid that was removed?

_

WORKSTATION 2 POWER STEERING ANALYZER

DIRECTIONS: Complete Workstation 2 at the computer station.

SUMMARY: In this activity you will complete a computer-based scenario, this workstation contains one scenario.

z As you complete the scenario you will be directed to answer questions in your workbook

1 What was the customers concern?

_

2 Fill in the specification table below before you start the computer-based scenario

S N O I T A C I F I C E P S

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LESSON ONE WORKSTATION 2

3 Fill in the table below as you go through the computer based scenario

4 Did you replace any components? If so, which one(s) and why?

WORKSTATION 3 BALL JOINT INSPECTION

DIRECTIONS: Complete Workstation 3 at a vehicle workstation.

SUMMARY: In this activity you will use the workshop manual/ball joint job aid to inspect the workstation

vehicle

z Refer to the ball joint job aid to answer questions 1 and 2

1 According to the front suspension job aid, what component(s) should you inspect before checking balljoint deflection?

_

2 According to the front suspension job aid, which vehicle(s) would require you to support the lowercontrol arm when checking for ball joint deflection?

_Perform a ball joint inspection on the workstation vehicle

3 Are there any visual signs of damage?

_Answer the following questions using the graphic below

4 When measuring for lower ball joint deflection on this vehicle, draw where you would place the tool(s)

in order to get a correct reading? Where would you apply pressure to get the reading?

_

5 When measuring for upper ball joint deflection on this vehicle, draw where you would place the tool(s)

in order to get a correct reading? Where would you apply pressure to get the reading?

_

LESSON ONE WORKSTATION 3

6 Measure upper and lower ball joint deflection on the workstation vehicle and record your readings in the tablebelow

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This workstation continues on the next page

z Using the 2006 Expedition workshop manual, answer the questions below.

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LESSON ONE WORKSTATION 4

WORKSTATION 4 SUSPENSION INSPECTION

DIRECTIONS: Complete Workstation 4 at the computer station.

SUMMARY: In this activity you will use the workshop manual to answer suspension and alignment questions.

z Using the 2006 Explorer workshop manual, answer the questions below

t n o r F r e b m a C

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5 What alignment adjustments can be made on this vehicle and how? Check all that apply

2006 Explorer

LESSON ONE WORKSTATION 4

z Using the 2006 Fusion workshop manual, answer the questions below

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s r e t s u j d a m a h t i w s l o h

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z Using the 2006 F-250 4x2 workshop manual, answer the questions below.

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LESSON ONE WORKSTATION 4

z Using the 2006 Focus workshop manual, answer the questions below

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C R a r o e s

d r e i t r o s n i e o

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21 Identify what could cause the tire wear patterns below.

Pattern (A)

Pattern (B)

_

LESSON ONE WORKSTATION 4

21 Identify what could cause the tire wear patterns below

Pattern (C)

Pattern (D)

_