Central Maine Community College Auburn, ME FOA 190 Brakes, Steering, Suspension & Drivelines. Course Syllabus

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1 Central Maine Community College Auburn, ME Automotive Ford/ASSET Term: Spring 18 FOA 190 Brakes, Steering, Suspension & Drivelines Instructor: Matt Walsh Course Syllabus Course Description This course consists of three major sections of instruction and lab experience. The first section teaches theory and operation of automotive brake systems including service and repair. The second section teaches front and rear suspension systems including electronic height and stability controls, manual, power steering systems and electronic steering systems ; wheel alignment; tire and wheel service and repair procedures. The third section teaches drivetrain basic principles and service; types of drivelines (FWD, RWD) and differentials; Pre-requisite: FOA 150 & FOA 151 or Instructor approval Course Specifications Credit hours assigned to the course Total hours scheduled for class meetings Projected shop hours Estimated hours required for outside work (reading, research, etc.) Total Estimated Hours of Student Effort (total lines 1, 2, 3) Course_Objectives The purpose of this course is to provide students with an opportunity to understand the principles of, gain experience with, and accurately perform services on the following specific objectives: Brake Systems fundamentals Drum and Disc Brake Systems Brake Warning Systems Power Assist Systems Brake Diagnosis/Service Anti-lock Brake Systems Front Suspension Systems Rear Suspension Systems Wheel Alignment Concepts and Adjustments Wheel / Tire Service Steering Gears/Power Steering/Electronic Steering and Suspension Diagnosis / Service

2 Electronic Ride Control / Rear Load Leveling / Air Suspension System Differential Diagnose / Repair Drivelines service / Repair NVH Fundamentals / Diagnosis NVH /Repair Student Learning Outcomes After successful completion of this course and all the following learning outcomes, the student will be able to: Brakes Check and adjust master cylinder levels. Check master cylinder for internal and external leaks and proper operation; determine needed repairs. Remove, bench bleed, and replace master cylinder. Diagnose poor stopping, pulling, or dragging caused by problems in the hydraulic system; determine needed repairs. Inspect brake lines and fittings for leaks, dents, kinks, rust, cracks, or wear; tighten loose fittings and supports. Inspect flexible brake hoses for leaks, kinks, cracks, bulging, or wear; tighten loose fittings and supports. Fabricate and install brake lines (double flare and ISO types), hoses, fittings, and supports as needed. Select, handle, store and install brake fluids to proper level. Inspect, test, and replace metering (hold-off), proportioning (balance), pressure differential, and combination valves. Inspect, test, replace, and adjust load or height sensing-type (load) proportioning valve. Inspect, test, and replace components of brake warning light system. Bleed, (manual, pressure, vacuum, or surge) and/or flush hydraulic system as needed. Diagnose poor stopping, noise, pulling, grabbing, dragging or pedal pulsation problems with a drum brake system; determine needed repairs. Remove, clean (using proper safety procedures), inspect, and measure brake drums; service or replace as needed. Mount brake drum on lathe and machine braking surface. Remove, clean, and inspect brake shoes/linings, springs, pins, clips, levers, adjusters/self-adjusters, and other related brake hardware; determine needed repairs, lubricate and reassemble. Clean and remove loose dirt, rust, or scale on brake backing (support) plates (using proper safety procedures); inspect; remove and reinstall if necessary. Remove and reinstall/replace wheel cylinders. Disassemble and clean wheel cylinder assembly; inspect parts for wear, rust, scoring, and damage; hone cylinder (if necessary and recommended by manufacturer); replace all cups, boots, and any damaged or worn parts. Lubricate brake shoe support pads on backing (support) plate, adjuster/self adjuster mechanisms, and other brake hardware.

3 Determine correct brake shoe application. Install brake shoes and related hardware. Adjust brake shoes and reinstall brake drums or drum/hub assemblies and wheel bearings. Reinstall wheel, torque lug nuts, and make final checks and adjustments. Diagnose poor stopping, noise, pulling, grabbing, dragging, or pedal pulsation caused by problems in the disc brake mechanical assembly; determine needed repairs. Remove caliper assembly from mountings; clean and inspect for leaks and damage to caliper housing. Clean and inspect caliper mountings and slides for wear and damage. Remove, clean, and inspect pads and retaining hardware; determine needed service. Remove, disassemble, and clean caliper assembly; inspect parts for wear, rust, scoring, and damage; replace all seals, boots, and any damaged or worn parts. Reassemble, lubricate, and reinstall caliper, pads, and related hardware. Clean and inspect rotor; measure rotor with a dial indicator and a micrometer. Refinish rotor according to manufacturer's recommendations. Adjust calipers with integrated parking brakes. Fill master cylinder with recommended fluid and seat pads; inspect caliper for leaks. Reinstall wheel; torque lug nuts. Test pedal free travel with and without engine running; check power booster operation. Check vacuum supply (manifold or auxiliary pump) to vacuum-type power booster. Inspect the vacuum-type power booster unit for vacuum leaks; inspect the check valve for proper operation; repair or replace parts as needed. Diagnose wheel bearing noises, wheel shimmy and vibration problems; determine needed repairs. Remove, clean, inspect, repack, or replace and pack wheel bearings, replace seals and adjust wheel bearings. Check parking brake cables and components for wear, rusting, binding and corrosion; clean, lubricate, and replace parts as necessary. Check parking brake operation; adjust as needed. Check operation of parking brake indicator light system. Check operation of brake stop light system; adjust and service as needed. Steering and Suspension Disable supplemental restraint system (SRS) in accordance with manufacturers' procedures. Diagnose power rack and pinion steering gear vibration, looseness, and hard steering problems; determine needed repairs. Inspect and replace steering shaft universal-joint(s), flexible coupling(s), collapsible column, lock cylinder mechanism, and steering wheel. Remove and replace manual or power rack and pinion steering gear; inspect mounting bushings and brackets. Disassemble, inspect, repair, and reassemble rack and pinion steering gear. Adjust manual or power rack and pinion steering gear.

4 Inspect and replace manual or power rack and pinion steering gear inner tie rod ends (sockets) and bellows boots. Inspect manual and power steering fluid levels and condition. Flush power steering system. Diagnose power steering fluid leakage; determine needed repairs. Inspect, adjust or replace and adjust power steering belt. Remove, inspect, and replace power steering pump and pump mounts. Inspect and replace power steering pump seals and gaskets. Remove, inspect, and replace power steering pump pulley; check alignment. Perform power steering system pressure test; determine needed repairs. Inspect and replace power steering hoses and fittings. Inspect and replace pitman arm, relay (centerlink/intermediate) rod, idler arm and mountings, and steering linkage damper. Inspect, replace, and adjust tie rod ends (sockets), tie rod sleeves, and clamps. Diagnose short and long arm-type suspension system noises, body sway, and uneven riding height problems; determine needed repairs. Diagnose MacPherson strut suspension system noises, body sway, and uneven riding height problems; determine needed repairs. Remove, inspect, and replace upper and lower control arms, bushings, shafts, and rebound bumpers. Remove inspect, adjust, and replace strut (compression/tension) rods and bushings. Inspect and replace upper and lower ball joints on short and long arm-type suspension systems. Remove, inspect and replace steering knuckle assemblies. Remove, inspect, and replace short and long arm suspension system coil springs and spring insulators. Remove, inspect, and replace stabilizer bar bushings, brackets, and links. Remove, inspect, and replace ball joints on MacPherson strut suspension system. Remove, inspect, and replace MacPherson strut cartridge or assembly, strut coil spring, and insulator. Lubricate suspension/steering systems. Remove, inspect, and replace rear suspension system coil springs and spring insulators. Remove, inspect, and replace rear suspension system transverse links, control arms, bushings, and mounts. Remove, inspect, and replace rear MacPherson strut cartridge or assembly, strut coil spring, and insulators (silencers). Inspect and replace shock absorbers. Remove, inspect, and service or replace front or rear wheel bearings. Diagnose vehicle wandering, pulling, hard steering, and poor steering return problems; determine needed repairs. Measure vehicle riding height; determine needed repairs. Check and adjust front and rear wheel camber on suspension systems with a camber adjustment.

5 Check and adjust caster on suspension systems with a caster adjustment. Check and adjust front wheel toe; adjust as needed. Center steering wheel. Check toe-out-on-turns (turning radius); determine needed repairs. Check SAI (steering axis inclination)/kpi (king pin inclination) and included angle; determine needed repairs. Check and adjust (where applicable) rear wheel toe. Check rear wheel thrust angle; determine needed repairs. Check for front wheel setback; determine needed repairs. Check front cradle (sub-frame) alignment; determine needed repairs. Diagnose unusual tire wear patterns; determine needed repairs. Inspect tires; check and adjust air pressure. Diagnose wheel and tire vibration (shimmy and tramp) problems; determine needed repairs. Rotate tires according to manufacturer's recommendations. Measure wheel, tire, axle, and hub runout; determine needed repairs. Diagnose tire pull (lead) problems; determine corrective actions. Balance wheel and tire assembly (static and dynamic). Dismount, inspect, repair, and remount tire on wheel. Reinstall wheel; torque lug nuts. Driveline Diagnose differential case assembly noise and vibration problems; determine needed repairs. Remove, inspect, measure, adjust and reinstall differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case assembly. Diagnose constant-velocity (CV) joint noise and vibration problems; determine needed repairs. Diagnose universal joint noise and vibration problems; determine needed repairs. Diagnose front wheel drive (FWD) bearing noise and vibration problems; determine needed repairs. Inspect, service, and replace front wheel drive (FWD) and rear wheel drive (RWD) shafts, yokes, and boots. Inspect, service, and replace shaft center support bearings. Diagnose noise and vibration problems; determine needed repairs. Diagnose fluid leakage problems; determine needed repairs. Inspect and replace companion flange and pinion seal. Inspect ring gear and measure runout; determine needed repairs. Remove and inspect drive pinion gear, spacers, sleeves, and bearings. Measure and adjust drive pinion depth. Measure and adjust drive pinion bearing preload. Measure and adjust side bearing preload and ring and pinion backlash on a differential carrier assembly (threaded cup and shim types). Check ring and pinion tooth contact pattern; make needed adjustments.

6 Disassemble, inspect, measure, and adjust or replace differential pinion gears (spiders), shaft, side gears, side bearings, thrust washers, and case. Assemble and install differential case assembly; measure runout;determine needed repairs. Diagnose noise, slippage, and chatter problems; determine needed repairs. Inspect and flush differential housing; refill with correct lubricant. Inspect and reinstall clutch (cone or plate) components. Measure rotating torque; determine needed repairs. Diagnose rear axle shafts, bearings and seals for noise, vibration, and fluid leakage problems; determine needed repairs. Inspect and replace rear axle shaft wheel studs. Remove and replace rear axle shafts. Inspect and replace rear axle shaft seals, bearings, and retainers. Measure rear axle flange runout and shaft end play; determine needed repairs. Inspect, service, and replace front-wheel bearings and locking hubs. Noise Vibration and Harshness Define vibration terminology and concepts. Define noise terminology and concepts. Define harshness terminology and concepts. Describe the diagnostic process for NVH concerns. Describe road test procedures. Describe engine run-up tests. Describe the process for pinpointing vibration concerns. Perform vehicle frequency calculations Use Vibrate software to assist in diagnosing vibration concerns. Describe the process for pinpointing noise concerns. Describe the process for pinpoint harshness concerns. Topical Outline of Instruction Date Topic Assignment/Activity Week 1 Intro to Braking Systems Chapters 50 & 51 Begin brake learning outcomes Week 2 Brake Service and Diagnosis Chapters 52 & 53 Continue brake work Week 3 Intro to Steering and Suspension Chapters 45 & 46 Begin S/S learning outcomes Week 4 Steering and Suspension Service and Diagnosis Chapters 47 & 48 Continue S/S work Week 5 Vehicle Alignment Chapter 49, Alignment and alignment diagnosis Week 6 Driveline Service Chapter 40, Overhaul differential Week 7 NVH Ford STST curriculum, begin NVH learning outcomes Week 8 Review STST Evaluations, Final, Complete any shop work

7 Course Requirements Course task list shall be completed. A portfolio of all of the student s work will be passed in during the last class meeting. The student shall complete all class tests. CMCC Automotive Ford ASSET standards shall be met. Minimum ASE performance standards shall be successfully completed. Student Evaluation and Grading 70% Shop 30% Class Shop grading will be based on the successful performance of required tasks, shop test scores, general ability, attitude and participation. Written test scores and the completion of worksheets and homework assignments will determine class grading. I detailed rubric will be presented and discussed on the first day of class. It is the student s responsibility to ask for this rubric if they miss the first class. GPA Letter Numeric 4.0 A A B B B C C C D D Texts, Tools, and/or Supplies Automotive Technology a Systems Approach by Erjavec Students are required to purchase basic hand tools. A descriptive list is available from the instructor. Shop supplies & tools CMCC Performance Guide Office Hours Appointments can be made to accommodate student needs. They can be scheduled: in person by walk-in basis on Friday mornings during the regular Academic Calendar from 8:00 AM to 9:00 AM., voic at , at mwalsh@cmcc.edu

8 Disability Access Statement If you are a student with a documented disability and plan to request an academic or other accommodation, you must register as soon as possible with the CENTRAL MAINE COMMUNITY COLLEGE Disabilities Coordinator, Ms. Laura Rifkin. Visit the Coordinator s office, in Jalbert Hall or call for an appointment Note: The Disabilities Coordinator evaluates the request and supporting documentation to develop a reasonable accommodation(s). Accommodations are described, in detail, and put into a letter that is given to the student. The student is required to share the Disabilities Coordinator s letter, if requesting an accommodation and you should ask to read it. Affirmative Action Statement Central Maine Community College is an equal opportunity/affirmative action institution and employer. For more information, please call

9 Ethical Behavior Statement Central Maine Community College requires all students to adhere to high standards of integrity in their academic work. Activities such as cheating on exams and plagiarizing the intellectual work of others are not acceptable and will be subject to severe disciplinary actions up to and including dismissal Safety Specification for Lab and Classroom Safety glasses must be worn at all times while in the lab. Leather work shoes or boots must be worn at all times while in the lab. Hearing protection will be worn when appropriate. Dust mask will be worn when appropriate Please power down cell phones in the classroom and lab

CENTRAL MAINE COMMUNITY COLLEGE Auburn, ME Course Syllabus

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