Rack and Pinion Steering Inspection and Repair

JOB SHEET 187 Rack and Pinion Steering Inspection and Repair Name: --------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.3 4.B.5 4.B.6 4.B.9.4.B.18 4.B.8 Diagnose steering column noises, looseness, and binding concerns (including tilt mechanisms); determine necessary action. (P-2) Diagnose power steering gear (rack and pinion) binding, uneven turning effort, looseness, hard steering, and noise concerns; determine necessary action. (P-2) Inspect steering shaft universal joint(s), flexible coupling(s), collapsible column, lock cylinder mechanism, and steering wheel; perform necessary action. (P-2) Inspect and replace rack and pinion steering gear inner tie-rod ends (sockets) and bellows boots. (P-2) Inspect, replace, and adjust tie-rod ends (sockets), tie-rod sleeves, and clamps. (P-1) Remove and replace rack and pinion steering gear; inspect mounting bushings and brackets. (P-2) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly test, diagnose, inspect, and replace the components of a power rack and steering system and a steering column. Tools and Materials Service manual Technician's tool set Vehicle with a rack and pinion system (nonelectric) Tie-rod puller Torque wrench Power steering fluid Tape measure Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size 708

Job Sheet 187 709 PROCEDURE 1. Start the engine. Are there any noises when the steering wheel is turned back and forth? Check for the noise while driving at low speeds and stationary. 2. Check the lock cylinder and column tilt operation. 3. Straighten the wheels and turn the engine off. Move the steering wheel back and forth with little effort. Measure and record the steering wheel free play. I Maximum Free Play Specification 4. What could be wrong if the steering wheel has more free play than the specification? 5. Open the hood and have an assistant move the steering wheel back and forth. Look for steering column, joint, and/or coupling movement. Describe what you found. Upper steering column section \ Instrument 1/ I I panel Lower steering Flexible coupling gear Figure 66.18 Parts of a steering column. 6. Have the assistant move the steering wheel back and forth again. This time look for movement in the steering gear housing, rack and pinion mounts, and bushings. Describe what you found. 7. Describe the process required to repair the items that are worn.

710 Job Sheet 187 Inspect the pinion shaft extending from the steering gear by looking for leaks and attempting to move it. Does it move or have leaks? 9. Inspect the axle U-joints and/or the CV shafts. Describe how these components can affect the steering effort. 10. Inspect the bellows boots for cracks, leaks, or damage. Squeeze the bellows boots to see if there is fluid trapped inside them. Describe what you found. 11. Rock the tires back and forth to check for tie-rod looseness. Describe what you found. 12. Move the outer tie-rod ends by hand up and down. Do they have any looseness? Figure 66.3 Checking for tie-rod end wear. 13. Place the steering wheel holding mechanism (typically used in an alignment) to hold the steering wheel in place. 14. Hoist the vehicle in the air. Remove the front wheels. 15. Using the tie-rod end puller, remove the outer tie-rod ends.

Job Sheet 187 711 Figure 66.6 Using a tie-rod puller. 16. Remove the bellows boots and describe how to remove the inner tie-rod ends. There are many different styles. Tie-rod Socket seat Inner tierod end Figure 65.18 Two types of inner tie-rod sockets. Outer tie-rod threads here 17. Disconnect the steering column. 18. Disconnect the power steering lines and hoses (if applicable).

.19. 712 Job Sheet 187 Remove the fasteners from the rack and pinion unit. Remove the rack from the vehicle. Describe the condition of the mounts. Rubber mounts Sub-frame Rack and pinion Figure 65.7 The rack on this short-and-long arm sub-frame is mounted on rubber bushings. 20. Replace the rack mounts if they are worn. Reinstall the rack and pinion, lines, hoses, column parts, and tie-rod ends. 21. Add power steering fluid as necessary. Note: To bleed the air from the power steering system, refer to fob Sheet #190. 22. Does the vehicle require an alignment afterwards? Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments lnstructorname: ------------------------------------------------ Date: InstructorSignature: -----------------------------------------------------------------

Inspect Power Steering Fluid Level and Condition Name: --------------------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.10 Determine proper power steering fluid type; inspect fluid level and condition. (P-1) Performance Objective(s) Upon completion of this Job Sheet, you will be able to understand how to add the correct type of fluid to a power steering system and determine the fluid's condition. Tools and Materials Shop rag Service manual Proper type of power steering fluid Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. With the engine running and the hood open listen to the power steering pump. Sometimes a low fluid condition can cause a noise. 51

52 Job Sheet 12 2. Turn the engine off and check the power steering fluid level. Is it low, overfilled, or okay? Figure 13.7 The dipstick for the power steering has hot and cold levels. 3. Describe the condition of the fluid by smelling and touching it. Describe if it smells burnt or if it shows signs of metal in the ±1uid. "' 0 N "' c ~ m I u @ 4. Explain what could possibly cause the power steering ±1uid to become contaminated or aerated (foaming). 5. Refer to the service manual. What type of power steering ±1uid does the manufacturer suggest and at what interval does it suggest for replacement or inspection? 6. If the power steering level is low, add the correct type of power steering ±1uid to the reservoir. 7. Start the engine and let it run for a minute. Turn the engine off and recheck the fluid level. 2012, Cengage Learning, Inc. Licensed for one-tirne use by the purchaser only; no additional copying or retransmission is permitted.

Job Sheet 12 53 8. Check the power steering hoses for leaks. Remote reservoir Pressure hose Problems Encountered Figure 13.6 Parts of a power steering system include the pump and fluid reservoir. INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ------------------------- Date: Instructor Signature: ----------------------------------

JOB SHEET 190 Power Steering Diagnosis Name: Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.ll 4.B.12 4.B.13 4.B.14 4.B.15 Flush, fill, and bleed power steering system. (P-2) Diagnose power steering fluid leakage; determine necessary action. (P-2) Remove, inspect, replace, and adjust power steering pump belt. (P-1) Remove and reinstall power steering pump. (P-2) Remove and reinstall pressed-fit power steering pump pulley; check pulley and belt alignment. (P-2) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly test the power steering pump pressure; diagnose leakage concerns; flush, fill, and bleed the power steering system; and remove and reinstall the power steering pump. Tools and Materials Service manual Technician's tool set Power steering pressure test gauge Thermometer Power steering fluid Belt tension tools Pulley press/removal tool Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size 721 2012, Cengage Learning, Inc. Licensed for one-time use by the purchaser only; no additional copying or retransmission is permitted.

722 Job Sheet 190.PROCEDURE 1. What type of power steering fluid is recommended for this vehicle? 2. Start the engine and turn the wheels back and forth while stationary. Did you hear any noises?. 3. Turn the engine off. Open the hood and inspect the power steering hoses, lines, and pump housing. Did you find any leaks? Shaft seal power steering pump Figure 66.25 Power steering pump seals. 4. Record the power steering belt tension (or serpentine belt tension if equipped). 5. Compare your reading to the specification. 6. Describe the condition of the belt. Does it need replacement? 7. Explain how a loose power steering belt could cause a power steering pressure problem. 8. Is the power steering fluid level correct?

Job Sheet 1 90 723 9. Is the power steering fluid foamy or does it have metal shavings in it? 10. Install a thermometer in the power steering fluid. The temperature of the fluid should be at least 176 F (80 C). If the fluid is too hot, wait for it to cool down. 11. Install the pressure gauge and check the power steering pressure at 1,000 rpm and 3,000 rpm. Compare your readings to the specification. Pressure@ 1,000 rpm Specification Pressure @ 3,000 rpm Specification 12. Turn the steering wheel all the way to each side and record the pressure readings at 1,000 rpm in both directions. Pressure Turning Right Pressure Turning Left 13. Do these readings indicate a problem? 14. What service would you recommend given the results of the power steering pressure test? 15. Remove the pressure test gauge and disconnect the return hose. Hold the return hose in a position so that it drains into a drain pan. Place a plug in. the outlet on the pump housing. 16. Turn the engine on and move the steering wheel from side to side. The drain pan should fill with power steering fluid. 17. Turn the engine off. 18. Remove any belts and remove the power steering pump. 19. Remove the pulley by using the special pulley press removal tool. 20. Inspect the reservoir and pump housing for leaks and damage. What did you find?

724 Job Sheet 190.21. Reinstall the pulley and pump in the reverse order of removal. You will have to use the spedal tool to install a pressed pulley. Describe how difficult this was and what you may do different next time. 22. Reinstall the belt and any tensioners. 23. Fill the reservoir with the correct type of fluid. 24. Start the engine and run it at 1,000 rpm until the fluid comes out the return hose and into the drain pan. When you first start to see fluid, turn the engine off. 25. Remove the plug and reconnect the hoses. Fill the reservoir with fluid, start the engine, and turn the wheel side to side a few times to work the air out of the system. 26. Continue to do this until you do not see any foaming. Make sure that the fluid is full before finishing. Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested 0 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ----------------------- ~~~~M~:--------------------------------- Date:

Inspect and Replace Power Steering Hoses Name: Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.16 Inspect and replace power steering hoses and fittings. (P-2) Performance Objective(s) Upon completion of this Job Sheet, you will be able to understand how to inspect and replace the power steering hoses and fittings. Tools and Materials Shop rag Service manual Technician's tool set Oil catch pan Air blowgun Correct type of power steering fluid Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Inspect the power steering hoses for leaks by looking around the fittings area and the hoses themselves. Do they leak? 2. With the engine off, place the oil catch pan under the hoses and remove the power steering hoses. 3. Sometimes the hoses can be damaged intemally. With the hoses removed, use an air blowgun and force a low amount of pressure through the line. Can you feel the air on the other side of the hose? 127

128 Job Sheet 33 Replace the hoses if they show signs of leakage, links, damage, or soft spots. 5. Using the service manual as a guide, list the procedure and torque specifications (if any) for replacing the hoses. Note: Some power steering hoses have alignment marks when they are installed. 6. What is the proper type of power steering fluid that should be used with your vehicle? 7. Refill the power steering reservoir with the correct type of power steering fluid. 8. Start the engine and turn the steering wheel from lock to lock (left to right) several times. Check for fluid leaks and the fluid level when done. N ote: Fluid may need to be added as it is bled (rom the system. Problems Encountered Note: Some vehicles nzay require a variety o( procedures to bleed the systern. This may include driving the vehicle. Check the service manual and ask your instructor. INSTRUCTOR EVALUATION 0 4 Mastered Task 0 3 Able to Perform Task Independently; Some Additional Training Suggested 0 2 Able to Perform Task with Close Supervision; Requires Additional Training 0 1 Unable to Perform Task 0 0 Not Attempted Comments Instructor Name: Date: Instructor Signature: -------------------------------- 2012, Cengage Learning, Inc. Licensed for one-time use by the purchaser only; no additional copying or retransmission is permitted.

JOB SHEET 188 Conventional Steering Inspection and Repair Name: ---------------------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.4 4.B.17 4.B.7 Diagnose power steering gear (non-rack and pinion) binding, uneven turning effort, looseness, hard steering, and noise concern; determine necessary action. (P-2) Inspect and replace pitman arm, relay (centerlink/intermediate) rod, idler arm and mountings, and steering linkage damper. (P-2) Adjust non-rack and pinion worm bearing preload and sector lash. (P-3) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly test, diagnose, inspect, adjust, and replace the components of a conventional steering system. Tools and Materials Service manual Technician's tool set Vehicle with conventional steering Tie-rod puller Torque wrench Power steering fluid Beam-style torque wrench Pitman arm puller Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Start the engine. Are there any noises when the steering wheel is turned back and forth? Check for the noise while driving at low speeds and stationary. 7 1 3

714 Job Sheet 188 Straighten the wheels and turn the engine off. Move the steering wheel back and forth with little effort. Measure and record the steering wheel free play. I Maximum Free Play Specification 3. What could be wrong if the steering wheel has more free play than the specification? 4. Hoist the vehicle in the air and check for movement in the idler arm. Describe what you found. Figure 66.2 Checking an idler arm for looseness. 5. Check the inner and outer tie-rods for movement. Idler arm and bracket Center.link Pitman Steering arm Figure 65.10 Parts of a parallelogram steering system during a turn. 6. Check the center/intermediate link for joint movement.

7. Check the tie-rod adjusting sleeves for wear and rust. 8. Check the steering gearbox, hoses, and lines for leakage. Job Sheet 188 715 9. Check the pitman arm for spline wear and damage. Is the pitman arm you are working on a wear item? 10. Remove the pitman arm by using the special puller. Steering gear Pitman arm Figure 66.9 A pitman arm puller. 11. With the pitman arm removed, measure the worm gear bearing preload and sector lash. What are your measurements? 12. What does it mean if these measurements are outside of specification? 13. Describe how to adjust preload and sector lash.

.14. 716 Job Sheet 188 If needed, replace any items (as designated by your instructor) in the steering box. 15. Replace the components you removed in the reverse order. 16. Add power steering fluid as necessary. Note: To bleed the air from the power steering system, refer to Job Sheet #190. 17. Does the vehicle require an alignment afterwards? Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ------------------------ Date: Instructor Signature: ---------------------------------

JOB SHEET 183 Ball Joint, Control Arm, and Spring Inspection and Repair Name: ---------------------------- Station: --------------------- Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.C.5 4.C.6 4.C.3 4.C.7 Remove, inspect, and install upper and/or lower ball joints. (P-1) Remove, inspect, and install steering knuckle assemblies. (P-2) Remove, inspect, and install upper and lower control arms, bushings, shafts, and rebound bumpers. (P-2) Remove, inspect, and install short-and-long arm suspension system coil springs and spring insulators. (P-3) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly remove and reinstall (or replace) the control arms, bushings, ball joints, steering knuckle, springs, and transverse links. Tools and Materials Service manual Technician's tool set Ball joint removal and replacement tools Control arm removal tools Shop press Dial indicator Torque wrench RWD vehicle with SLA suspension Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size 695

G9G Job Sheet 183.PROCEDURE 1. Raise the vehicle in the air on a drive-on alignment hoist. 2. Position the jack on the desired spot for testing ball joints. 3. Mount the dial indicator to measure the amount of lower ball joint looseness. Record the measurement and compare it to specifications. Spring above Loadcarrying ball joint Follower ball joint Spring on \ lower control \ arm _ ~ Follower 8 ball joint :::; ~ Figure 64.25 Unloading a ball joint to check for wear when the spring is above the upper control arm. Worn "iii ~ If Sintered Load- Figure 64.26 Unloading a ball joint to check for wear when the spring is on the lower control arm. Good Wear indicator Figure 64.27 Checking a wear indicator ball joint. Ball Joint Movement--------------- Specification------------------ 4. Repeat the same procedure for the upper ball joint. Record the measurement and compare it to specifications. Ball Joint Movement--------------- Specification------------------

Job Sheet 183 697 5. If the system you are working on is a "wear indicator" type, check the amount of wear shown on the ball joint. Record it and compare it to specifications. Is it worn? 6. Try to rock the tire back and forth and up and down. Does there seem to be movement? 7. Place the jack under the control arm and raise the jack until the ball joints are unloaded. 8. Remove the other components that are needed. This may include the caliper, rotor, and axle as necessary. 9. Loosen and remove the steering knuckle by removing the upper and lower ball joints. 10. Remove the control arms by removing the bolts holding the bushings in place. 11. The coil springs should be removed at this time. Inspect the coil springs. Are they cracked or damaged in any way? 12. Inspect the coil spring insulators (if applicable). Are they damaged? Coil spring upper seat insulator Coil spring lower seat insulator Figure 64.38 Insulators sometimes fit into the spring seats.

698 Job Sheet 183 13. Describe how the ball joints are fastened to the control arms. Pressed-fit Rivet or bolt Threaded Figure 64.29 Three common ball joint retaining methods. 14. Using the service manual as a guide, remove the ball joints from the control arm. Describe how you did this. Include any special tools that you used. 15. With the ball joints removed, inspect the control arm and the bushings. If the bushings need replacement, describe how they can be removed and how new ones can be installed. 16. Replace the control arm bushings if needed. 17. Check the steering knuckle for wear. How do you know if the steering knuckle is worn and needs replacement? 18. Prepare the control arms for reinstallation of the ball joints. Reinstall the ball joints as outlined in the manufacturer's service procedures. 2012, Cengage Learning, Inc. Licensed for one-time use by the purchaser only; no additional copying or retransmission is permitted.

Job Sheet 183 699 19. Install the upper and lower control arms into the vehicle. Torque the fasteners to specification. 20. Install the steering knuckle and make sure to use new grease and cotter pins. Torque the ball joints and control arms to specification. 21. Reassemble the remaining components, including the wheel. List the components you had to reassemble and their torque spedfications. Component Torque Specification Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested 0 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task 0 0 Not Attempted Comments Instructor Name: ------------------------ Date: Instructor Signature: ----------------------------------

JOB SHEET 181 Strut Inspection and Replacement Name: -------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.C.10 4.C.4 Remove, inspect, and install strut cartridge or assembly, strut coil spring, insulator (silencers), and upper strut bearing mount. (P-1) Remove, inspect, and install strut rods and bushings. (P-2) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly remove and reinstall (or replace) the struts on the front and rear of a vehicle. Tools and Materials Service manual Technidan's tool set Vehicle with front and rear struts Torque wrench Protective Clothing /Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Jounce the vehicle on the ground, release it, and then watch the car bounce. It should stabilize itself rather quickly. In most instances, this test is sufficient to test struts, but it is not a test that is completely reliable. 2. Does the vehicle have a strut cartridge or a Macpherson strut? 688

Job Sheet 181 689 3. Does a test-drive indicate that the struts may be worn? 4. What is the recommended service interval for inspection or replacement? 5. Do the tires indicate that the struts may be worn? 6. Raise the vehicle on a hoist and check the struts for leakage, bent rods, bad bearings, torn boots, or broken mounts. Note: To check the Macpherson strut for leakage, look under the boot. To check the strut cartridge you might have to remove the strut. 7. Remove the wheel and, using the service manual as a guide, describe the procedure to remove the strut. Note: Most Macpherson struts are removed as an assembly and some cartridges are removed from the top. Figure 64.11 The entire strut assembly is removed from the car.

690 Job Sheet 181 Prior to loosening the strut assembly, make alignment marks on the chassis. These marks should be placed on the lower strut bolts and the upper strut mount. Figure 64.12 Prior to loosening the strut-to-chassis bolts, make an alignment mark on one strut bolt and the chassis. 9. After the strut assembly has been removed, use a strut compressor to compress the coil spring. The top mount can now be loosened. Figure 64.15 A Macpherson strut compressor, sometimes called a clamshell. 10. With everything disassembled, perform your inspections on the following components. Component Coil Spring Strut Bearing Plate Fasteners Mounting Flanges Describe the Condition

Job Sheet 181 691 11. Reinstall (or replace with new) the coil spring, Macpherson strut, and mounting plate. List the torque specifications for the components you used here. 12. Reinstall the assembly into the vehicle. Were you able to align the assembly with the timing marks? 13. Should an alignment check be performed after you are done? Why or why not? 14. Check your work and then reinstall the wheel and torque it to the specification. 15. Test-drive the vehicle to ensure everything went okay. Problems Encountered INSTRUCTOR EVALUATION 0 4 Mastered Task 0 3 Able to Perform Task Independently; Some Additional Training Suggested 0 2 Able to Perform Task with Close Supervision; Requires Additional Training 0 1 Unable to Perform Task 0 0 Not Attempted Comments lnstructorname: ------------------------------------------------ Date: Instructor Signature: -----------------------------------------------------------------

JOB SHEET 185 Torsion Bar Removal, Installation, and Adjustment Name:-------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.C.8 Remove, inspect, install, and adjust suspension system torsion bars; inspect mounts. (P-3) Performance Objective(s) Upon completion of this Job Sheet, you will be able to understand how to properly remove, inspect, install, and adjust a torsion bar and its mounts. Tools and Materials Service manual Technician's tool set Vehicle with adjustable front torsion bar suspension Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Raise the vehicle on a hoist. 2. Release the pressure on the torsion bars by unscrewing the torsion bar adjusting screw. 3. Remove the adjusting screws and loosen the torsion bar mounts. 4. Remove the crossover plate that the torsion bar mounts are in. 704

Job Sheet 1 85 705 5. Remove the torsion bars by pulling them from the front control arms. 6. Carefully inspect the torsion bars, mounts, and adjusting screws for wear or cracks. Look carefully at the ends of the bars. Describe what you found. 7. Reinstall the torsion bar, mounts, and adjusting screws in the reverse order. 8. Lower the vehicle to the ground. 9. Using a tape measure (or an alignment machine), check the front ride height. Does it need to go up or down? 10. Explain how turning the adjustment screw will increase or decrease ride height. 11. Adjust the ride height up or down as needed with the vehicle off the ground and checking the measurement on the ground. Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ------------------------ Date: Instructor Signature: ---------------------------------

JOB SHEET 182 Stabilizer Bar and Links Inspection and Repair Name: ------------------------- Station: Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.C.9 Remove, inspect, and install stabilizer bar bushings, brackets, and links. (P-2) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly remove and reinstall (or replace) the stabilizer (sway) bar and links on a vehicle. Tools and Materials Service manual Technician's tool set Dial caliper Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size 692

Job Sheet 182 693 PROCEDURE 1. Raise the vehicle in the air. Inspect the condition of the stabilizer bar, the bushings, and the links. Describe their condition. Large cracks or splits in stabilizer link bushings Bushing walking out of bracket Large crack and splits Bushing wallowed out missing components ~----------------------------------------------------------------------------~ ~ Figure 64.22 Inspect stabilizer bushings. g. ~ i 2. Do you think the stabilizer links, bushings, and bar were worn to the point where they could have caused a noise? 3. Remove the stabilizer links first. Describe what they are fastened to. 4. Remove the stabilizer bushings. 5. Inspect the stabilizer (sway) bar for cracks, chunks missing, and corrosion. Use a steel brush and clean the bar. 6. Measure and record the outside diameter of the stabilizer bar where the bushings were mounted. Note: You may need this information to order replacement parts. 7. Reinstall the bushings and the stabilizer bar. What is the torque specification for the bushings? 8. Reinstall the stabilizer links to the bar. What is the torque specification for the bushings?

694 Job Sheet 182 Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ------------------------ Date:.InstructorSignature: ----------------------------------------------------------------

;,_ JOB SHEET 186 Leaf Spring Removal, Inspection, and Installation Name: Station: --------------------- Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.C.ll Remove, inspect, and install leaf springs, leaf spring insulators (silencers), shackles, brackets, bushings, and mounts. (P-3) Performance Objective(s) Upon completion of this Job Sheet, you will be able to understand how to properly remove, inspect, and install rear leaf springs. Tools and Materials Service manual Technician's tool set Adjustable tall jack stands Vehicle with rear multiple leaf spring suspension Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE I. Raise the vehicle on a hoist. Task Completed 2. Place tall jack stands on the rear axle for support. 3. Spray penetrant spray liberally on all of the bolts. 4. Remove the bolts holding the rear shackles and leaf spring perches. 708 Task Completed Task Completed

Job Sheet 186 707 5. Slightly lower the jack stands (if adjustable spinning type) so that the leaf springs pivot slightly. Caution: Leaf springs carry a lot of sprung weight. Be careful and move slowly when removing them. 6. Now remove the front leaf spring bushing bolts. 7. With the leaf springs removed from the vehicle, inspect the bushings, mounts, perches, and individual springs for damage and wear. Make sure to check the individual springs because they may be cracked in the middle where you cannot easily see them. Describe what you found. 8. Use the reverse procedure to install the leaf springs. 9. Tighten all bolts to specification. Problems Encountered INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments Instructor Name: ------------------------ Date: Instructor Signature: ---------------------------------

JOB SHEET 180 Shock Absorber Inspection and Replacement Name: ---------------------------- Station:--------------------- Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.D.l Inspect, remove, and replace shock absorbers. (P-1) Performance Objective(s) Upon completion of this Job Sheet, you will be able to properly diagnose and replace a shock absorber. Tools and Materials Service manual Technician's tool set Vehicle with front or rear shock absorbers Tall jack stands Torque wrench Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Jounce the vehicle on the ground, release it, and then watch the car bounce. It should stabilize itself rather quickly. In most instances, this test is sufficient to test shock absorbers, but it is not a test that is completely reliable. 2. Does a test-drive indicate that the shock absorbers may be worn? 3. What is the recommended service interval for inspection or replacement? 685

686 Job Sheet 180 4. Do the tires indicate that the shock absorbers may be worn? 5. Raise the vehicle on a hoist and check the shock absorbers for leakage, bent rods, or broken mounts. 6. Spray the shock absorber bolt with a penetrant spray. 7. Support the rear axle by placing the tall jack stands under it. 8. If replacing the shock with a new one, compare the new shock absorber to the old one. Note: Shock absorbers should only be replaced in pairs. 9. Refer to the service manual for the specific procedures for removal of the shock and perform them. 10. Install the new shock absorber and tighten the fasteners to specification. Note: Sometimes loweling the vehicle is needed to remove and install the upper fastener. Task Completed 11. Lower the vehicle and bounce it a few times. Does it make any noise? 12. Test-drive the vehicle. Does it ride smoother? Problems Encountered D INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D D 2 Able to Perform Task with Close Supervision; Requires Additional Training 1 Unable to Perform Task 0 Not Attempted

Comments Job Sheet 180 687 Instructor Name: Instructor Signature: Date:

JOB SHEET 191 Hybrid Electric Vehicle Electric Steering Operation and Safety Name: --------------------------- Station:--------------------- Date: NATEF Correlation This Job Sheet addresses the following NATEF task(s): 4.B.20 4.B.21 Inspect and test electric power assist steering. (P-3) Identify hybrid vehicle power steering system electrical circuits, service, and safety precautions. (P-3) Performance Objective(s) Upon completion of this Job Sheet, you will be able to describe how a hybrid electric vehicle's electric steering operates and how to identify and diagnose it. Your instructor may give you a specific make and model to work with. Tools and Materials Service manual Scan tool High-voltage gloves Protective Clothing/Equipment Goggles or safety glasses with side shields Describe the vehicle being worked on: Year Make Model VIN Engine type and size PROCEDURE 1. Describe how the electric power steering on this hybrid electric vehicle operates. 725

726 Job Sheet 191 2. How much voltage does the electric steering operate with? 3. What is the source of the voltage for the steering motor? 4. What advantages does electric power steering have over conventional hydraulic power steering systems? 5. Locate the electric power steering motor and related wiring on the vehicle. 6. Inspect the wiring and motor. 7. What color are the wires and connectors? 8. Connect a scan tool and check for any DTCs related to the power steering system. List them here. 9. Using the service manual as a guide, locate and list any TSBs related to the electric power steering system here. 10. Using the service manual, describe ay safety precautions that should be taken when working on or around the electric power steering system on a hybrid electric vehicle. Problems Encountered

Job Sheet 191 727 INSTRUCTOR EVALUATION D 4 Mastered Task D 3 Able to Perform Task Independently; Some Additional Training Suggested D 2 Able to Perform Task with Close Supervision; Requires Additional Training D 1 Unable to Perform Task D 0 Not Attempted Comments InstructorName: ------------------------------------------------ Date: ------------- ~nstructorsignature: -----------------------------------------------------------------