Suspension and Steering
Systems
SYLLABUS
Your Course Learning Plan
85302AA
A. General Course Information
Course description:
The Steering and Suspension students of UAW-LETC will successfully complete a
series of activities that will meet the needs of Automotive Dealerships and the
aftermarket while following guide lines of the National Automotive Training and
Education Foundation (NATEF). These activities will consist of, but not limited to,
diagnostics, repair and/or replacement, and adjustment to factory specifications.
These activities will take place in the classroom and shop, consisting of written and
hands-on exercises. Each phase will have its guidelines and time period. We will
cover some areas with more detail than others depending on the demand for that
area.
Prerequisites:
Technical Introduction to Dealerships: Module 7, Steering Systems Module 8, and
Suspension Systems. (Refer to TID Curriculum for more information)
Organization:
This is a lecture / shop course in which topics are presented by the instructor, shop
assignments are explained and assigned projects are completed by students both
during class and shop time. Objective quizzes are given at the completion of each
section and there is a comprehensive final exam. When students have completed
this course they generally have the same level of expertise as those who have
experience in the automotive industry. Initial emphases are on the use of equipment
and fundamental procedures.
Course objectives:
1. Demonstrate the skill to diagnose and repair automotive suspension, steering /
tire and wheel systems using approved resources, tools, and procedures.
2. Demonstrate a working understanding of suspension, steering / tire and wheel
system design and operation.
3. Exhibit the skill to perform Steering, suspension / tire and wheel system service.
4. Explain and demonstrate the procedures for performing alignments.
Textbooks / Software:
1. Toyota Course 453, Technician Handbook
2. Auto Suspension and Steering Textbook.
3. Video Library.
B. Course Content and Outcomes
Course content:
Learning outcomes:
Grading (credit) criteria:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Tire and Wheel Basics
Tire and Wheel Service
Suspension System Basics
Suspension System Components
Front Suspension Systems
Rear Suspension Systems
Electronic Suspension Systems/Service
Steering System Basics
Wheel Alignment Principles
Wheel Alignment Procedures
Front Suspension System Service
Rear Suspension System Service
Driveline and Wheel Components/Service
Steering Linkage and Manual Steering Gear Service
Power Steering and Four-Wheel Steering Service
Upon successful completion of this course the student will:
1. Demonstrate and practice personal responsibility skills required at the
workplace.
2. Practice interpersonal communication and problem solving skills.
3. Utilize social and personal management skills.
4. Implement a diagnostic strategy that will aid in identification and location of
faults in the Toyota Wheel and Tire system.
5. Demonstrate the skill to follow proper procedures in the repair of Toyota Wheel
and Tire systems.
6. Implement a diagnostic strategy that will aid in identification and location of
faults in the Toyota Steering system.
7. Demonstrate the skill to follow proper procedures in the repair of Toyota
Steering systems.
8. Possess the skills necessary to perform Suspension and steering system
service and repair in line with the highest quality standards in the automotive
industry.
Course will be weighted as follows. Worksheets 40%, Quizzes 30%, homework
10%, and final exam 20%.
Worksheets will be assigned almost every day. Worksheets will be due at the end of
each day. Grading will be based on a performance rating of 2 (Proficient) and 3
(Proficient, able to teach others) with a minimum rating of 2 being required for
passing. (Extra credit will be given for a rating of 3).
There will be many objective quizzes given relating to current topics. Grading will be
based on percentage of correctly answered questions.
The final exam will be comprehensive relating to all topics covered in the course.
Questions are written with heavy emphasis on critical thinking and diagnostic skills.
A grade of 80% is required for passing.
C. Class/Shop Policies
Student Expectations:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Be on time for the start of class and return to class for final roll call.
Wear safety glasses in the shop at all times.
Appropriate working attire shall be worn.
Access to shop vehicles only as authorized by the instructor.
No cell phones or other electronic devices.
Participate in classroom discussions.
Observe classroom etiquette.
Participate in shop clean up.
Attendance to shop activities in assigned area.
Approval by instructor required prior to being absent from assigned area.
Clean all tools prior to returning them to the tool crib.
Follow all safety rules; be concerned with your safety and the safety of others.
Report all injuries regardless of the nature or severity to the instructor.
D. Other resources
Online resources:
Techinfo.Toyota.Com
GMTraining.Com
Tentative Schedule
DAY
1
TASK
Worksheet SS-F2, Inspect Tires,
Check and Adjust Air Pressure
Worksheet SS-F1, Identify and
Diagnose Tread Wear Patterns
TOPIC/ACTIVITY
Tire and Wheel Basics
Anatomy of a Tire
Quiz: Tire and Wheel Basics
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 1, Tire and Wheel Service Basics, pages 1-1
through 1-12
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 2, Tire and Wheel Service, pages 2-1 through 2-23
2, 3
Toyota Worksheet 2-1, Checking
Machine Calibration
Toyota Worksheet 2-2, Typical
Dynamic Balance Procedure
Toyota Worksheet 2-3, Adhesive
Weight Balancing
Toyota Worksheet 2-4, Measuring
Tire Run-out
Toyota Worksheet 2-5, Measuring
Wheel Run-out
Toyota Worksheet 2-6, Measuring
Hub Run-out
Toyota Worksheet 2-7, Road Force
Variation Measuring
Worksheet SS-F4-10, Tire Rotation
Worksheet SS-F3-6, Diagnose
Wheel/Tire Vibrations, Shimmy,
Noise and Tire Pull
Tire and Wheel Service
Tire Rotation
Wheel Balance
Tire & Wheel Run-out
Replacement & Repair
Quiz: Tire and Wheel Service
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 2, Tire and Wheel Service, pages 2-24 through 2-44
2, 3
continued
Worksheet SS-F13, Inspect,
Diagnose and Calibrate Tire
Monitoring System
Worksheet SS-F8-9-10-11-12,
Dismount, Inspect, and Remount
Tire
Worksheet SS-B2, Vehicle Service
Information
Suspension System Basics
Quiz: Suspension Designs
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 3, Suspension System Basics, pages 3-1 through 316
Text: Auto Suspension and Steering Textbook, Chapter 1, Basic
Suspension and Steering System Operation, pages 11-18 and 20-23
Toyota Worksheet 4-2: Front
Suspension Component Inspection
Worksheet SS-D1, Ball Joint
Inspection
Worksheet SS-D2, Spring
Inspection
Suspension System Components
Worksheet SS-D4, McPherson
Strut/Shock Absorber Inspection
Front Suspension Systems
Rear Suspension Systems
Electronic Suspension Systems/Service
Quiz: Suspension Components
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 3, Suspension System Basics, pages 3-17 through
3-27
Text: Auto Suspension and Steering Textbook, Chapter 4, Common
Suspension System Components, pages 67-84
Quiz: Front and Rear Suspensions
Text: Auto Suspension and Steering Textbook, Chapter 5, Front
Suspension Systems, pages 85-101
Text: Auto Suspension and Steering Textbook, Chapter 7, Rear
Suspension Systems, pages 127-146
Text: Auto Suspension and Steering Textbook, Chapter 14, Electronic
Suspension and Steering Systems, pages 301-310
Text: Auto Suspension and Steering Textbook, Chapter 15, Electronic
Suspension and Steering Service, pages 319-330
7
Toyota Worksheet 8-2, Chassis
Inspection
Steering System Basics
Quiz: Steering System Basics and Components
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 5, Steering System Basics, pages 5-1 through 5-7
Text: Auto Suspension and Steering Textbook, Chapter 9, Steering
Systems, pages 174-182
Steering System Basics (continued)
Quiz: Power Steering and Steering Columns
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 5, Steering System Basics, pages 5-8 through 5-27
Text: Auto Suspension and Steering Textbook, Chapter 9, Steering
Systems, pages 167-173 and 183-200
Text: Auto Suspension and Steering Textbook, Chapter 14, Electronic
Suspension and Steering Systems, pages 310-315
9
Toyota Worksheet 7-1, Alignment
Geometry
Toyota Worksheet 7-3, Interpreting
Wheel Alignment Values and
Service Information
Wheel Alignment Principles
Quiz: Alignment Basics
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 7, Vehicle Dynamics and Handling, pages 7-1
through 7-31
Text: Auto Suspension and Steering Textbook, Chapter 16, Wheel
Alignment Principles, pages 343-360
10, 11
12
13
14
15
Toyota Worksheet 9-1, Wheel
Alignment Demonstration
Toyota Worksheet 10-2,
Diagnosing Using SAI and IA
Toyota Worksheet 10-1, Measuring
Steering Axis Inclination and
Included Angle
Worksheet SS-E2, Alignment
Wheel Alignment Procedures
Toyota Worksheet 4-1, Dry
Park/Steering Linkage Inspection
Toyota Worksheet 4-2, Front
Suspension Component Inspection
Front Suspension System Service
Worksheet SS-D1j, R&R Strut
Assembly Spring
Worksheet SS-D3a, R&R Shock
Absorber
Worksheet SS-E2, Alignment
Front Suspension System Service (continued)
Worksheet SS-D1e, R&R Ball
Joints
Worksheet SS-D1f, R&R Steering
Knuckle
Worksheet SS-E2, Alignment
Front Suspension System Service (continued)
Worksheet SS-D1c, R&R
Upper/Lower Control Arms
Worksheet SS-E2, Alignment
Front Suspension System Service (continued)
Quiz: Alignment Procedures
Text: Auto Suspension and Steering Textbook, Chapter 17, Wheel
Alignment Procedures, pages 361-389
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 4, Suspension System Service, pages 4-1 through
4-11
Text: Auto Suspension and Steering Textbook, Chapter 6, Front
Suspension System Service, pages 103-108
Text: Auto Suspension and Steering Textbook, Chapter 6. Front
Suspension System Service, pages 110-113
Text: Auto Suspension and Steering Textbook, Chapter 6, Front
Suspension System Service, pages 113-117
Text: Auto Suspension and Steering Textbook, Chapter 6, Front
Suspension System Service, pages 117-121
16
17
Worksheet SS-D7, Solid and Twin
I-Beam Suspension (IN-CLASS)
Worksheet SS-D1i, R&R Stabilizer
Bar and Bushings
Worksheet SS-D1d, R&R Strut
Rods and Bushings
Worksheet SS-E2, Alignment
Worksheet SS-D8, Kingpin Service
(IN-CLASS)
Front Suspension System Service (continued)
Worksheet SS-D6, Rear
Suspension Component Inspection
Rear Suspension System Service
Text: Auto Suspension and Steering Textbook, Chapter 6, Front
Suspension System Service, pages 121-125
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 4, Suspension System Service, pages 4-13 through
4-26
Text: Auto Suspension and Steering Textbook, Chapter 8, Rear
Suspension System Service, pages 147-151
18, 19
20
21, 22
23
Toyota Worksheet 4-3, Adjusting
Ride Height Rear Air Suspension
Worksheet SS-D2b, R&R
Transverse Link
Worksheet SS-E2, Alignment
Rear Suspension System Service (continued)
Worksheet SS-D3b, Remove,
Inspect and Replace Wheel
Bearings
Worksheet SS-D9, Drive Shaft
Inspection
Worksheet SS-D10, CV Axle
Inspection
Driveline and Wheel Components/Service
Toyota Worksheet 6-1, Toyota Dry
Park Inspection
Toyota Worksheet 8-1, Test Drive
Worksheet SS-C4, Diagnose
Power Steering Gear (non Rack
and Pinion)
Worksheet SS-C18, R&R Tie-Rods
(non Rack and Pinion)
Worksheet SS-C9, R&R Tie-Rods
(Rack and Pinion)
Worksheet SS-C17, R&R
Parallelogram Steering
Components
Worksheet SS-C5, Diagnose Rack
and Pinion Steering Complaint
Worksheet SS-E2, Alignment
Steering Linkage and Manual Steering Gear Service
Worksheet SS-C8, R&R Rack and
Pinion
Worksheet SS-E2, Alignment
Steering Linkage and Manual Steering Gear Service (continued)
Text: Auto Suspension and Steering Textbook, Chapter 8, Rear
Suspension System Service, pages 151-165
Text: Auto Suspension and Steering Textbook, Chapter 12, Driveline
and Wheel Components, pages 251-260
Text: Auto Suspension and Steering Textbook, Chapter 13, Driveline
and Wheel Service, pages 271-276 and 284-295
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 6, Steering System Service, pages 6-1 through 6-3
Text: Auto Suspension and Steering Textbook, Chapter 10, Steering
Linkage and Manual Gear Service, pages 203-207 and 212-215
Text: Auto Suspension and Steering Textbook, Chapter 10, Steering
Linkage and Manual Steering Gear Service, pages 215-220
24
25, 26
Worksheet SS-C6, Inspect
Steering Column
Worksheet SS-C3, Steering
Column Diagnosis
Worksheet SS-C1, Supplemental
Restraint System
Worksheet SS-C2, R&R Steering
Wheel
Worksheet SS-E2, Alignment
Steering Linkage and Manual Steering Gear Service (continued)
Toyota Worksheet 6-2, Power
Steering Fluid/Belt Inspection
Worksheet SS-C12, Diagnose
Power Steering Leaks
Worksheet SS-C16, R&R Power
Steering Hoses
Power Steering and Four-Wheel Steering Service
Text: Auto Suspension and Steering Textbook, Chapter 10, Steering
Linkage and Manual Steering Gear Service, pages 204-205 and 207212
Text: Toyota Course 453, Suspension, Steering & Handling Technician
Handbook, Section 6, Steering System Service, pages 6-4 through 6-8
Text: Auto Suspension and Steering Textbook, Chapter 11, Power and
Four-Wheel Steering Service, pages 225-235, 239, and 243-249
