AUTOMOTIVE , SUSPENSION, AND ALIGNMENT EIGHTH EDITION

James D. Halderman

A01_HALD4642_08_SE_FM.indd 1 13/11/19 5:08 PM Director of Product Management: Linea Rowe Product Manager, Trades, Hospitality, & Careers: Derril Trakalo Senior Analyst, HE Global Content, Trades & Hospitality: Tara Warrens Analyst, HE Global Content, Careers & Professional: Bridget Daly Manager Content HE, Careers & Professional: Jenifer Niles Director, Digital Studio & Content Production: Brian Hyland Managing Content Producer: Jennifer Sargunar Managing Producer, Teacher Education & Careers: Autumn Benson Content Producer (Team Lead): Faraz Sharique Ali Permissions Editor: Jenell Forschler Cover Design: Carie Keller, SPi Cover Credit: Courtesy of ASE; Henrik5000/E+/Getty images Full-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

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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 alignment Description: 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——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

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ISBN-10: 0-13-567464-6 ISBN-13: 978-0-13-567464-2

A01_HALD4642_08_SE_FM.indd 2 13/11/19 5:08 PM 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 and Wheels 53

chapter 5 -Pressure Monitoring Systems 78

chapter 6 Tire and 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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A01_HALD4642_08_SE_FM.indd 3 13/11/19 5:08 PM CONTENTS

chapter 1 ■■ Fire Extinguishers 33 ■■ Fire Blankets 34 SERVICE INFORMATION, WORK ■■ First Aid and Eye Wash Stations 34 ■■ ORDERS, AND VEHICLE Hybrid Safety Issues 35 Summary 40 IDENTIFICATION 1 Review Questions 40 ■■ Learning Objectives 1 Chapter Quiz 40 ■■ Key Terms 1 ■■ Owner’s Manuals 1 chapter 3 ■■ Service Information 2 ■■ Technical Service Bulletins 2 ENVIRONMENTAL AND ■■ Recalls and Campaigns 2 ■■ Work Order 3 HAZARDOUS MATERIALS 42 ■■ ■■ Service Records 3 Learning Objectives 42 ■■ Additional Information 5 ■■ Key Terms 42 ■■ Parts of a Vehicle 5 ■■ Hazardous Waste 42 ■■ Front-Wheel Drive Versus Rear-Wheel Drive 5 ■■ Federal and State Laws 42 ■■ Vehicle Identification 5 ■■ Asbestos Hazards 44 ■■ Vehicle Safety Certification Label 7 ■■ Used Fluid 45 ■■ VECI Label 7 ■■ Used Oil 45 ■■ Solvents 46 Summary 7 ■■ Coolant Disposal 47 Review Questions 8 ■■ Lead-Acid Battery Waste 48 Chapter Quiz 8 ■■ Fuel Safety and Storage 48 ■■ Airbag Handling 49 chapter 2 ■■ Used Tire Disposal 49 ■■ Air-Conditioning Refrigerant TOOLS AND SAFETY 9 Oil Disposal 50 ■■ Learning Objectives 9 Summary 52 ■■ Key Terms 9 Review Questions 52 ■■ Threaded Fasteners 9 Chapter Quiz 52 ■■ Hand Tools 13 ■■ Screwdrivers 16 ■■ Torx 17 chapter 4 ■■ Pliers 19 ■■ Basic Hand Tool List 22 TIRES AND WHEELS 53 ■■ Tool Sets and Accessories 23 ■■ Learning Objectives 53 ■■ Electrical Hand Tools 23 ■■ Key Terms 53 ■■ Hand Tool Maintenance 25 ■■ Introduction to Tires 53 ■■ Trouble Lights 25 ■■ Parts of a Tire 53 ■■ Air and Electrically Operated Tools 25 ■■ Tire Molding 56 ■■ Personal Protective Equipment 27 ■■ Service Description 58 ■■ Safety Precautions 28 ■■ High-Flotation Tire Sizes 58 ■■ Vehicle Protection 29 ■■ Load Index and Equivalent Loads 59 ■■ Safety Lifting (Hoisting) a Vehicle 29 ■■ Speed Ratings 59 ■■ Jacks and Safety Stands 31 ■■ Tire Pressure and Traction 60 ■■ Drive-On Ramps 31 ■■ Width and Tire Size 60 ■■ Electrical Cord Safety 32 ■■ Uniform Tire Quality Grading System 61 ■■ Jump Starting and Battery Safety 32 ■■ All-Season Tire Designation 63

iv

A01_HALD4642_08_SE_FM.indd 4 13/11/19 5:08 PM ■■ Types of Tires 63 ■■ Tire Replacement 100 ■■ DOT Tire Code 63 ■■ Tire Balancing 103 ■■ Tire Conicity and Ply Steer 64 ■■ Wheel Weights 103 ■■ Vehicle Handling and Tire Slip Angle 65 ■■ Wheel/Tire Balancers 106 ■■ Spare Tires 65 ■■ Tire Repair 107 ■■ Run-Flat Tires 66 Summary 115 ■■ General Motors TPC Rating 67 Review Questions 115 ■■ Tire Selection Considerations 68 Chapter Quiz 115 ■■ Noise-Reducing Tires 69 ■■ Wheels 69 ■■ Tire Valves 72 chapter 7 ■■ Unsprung Weight 73 ■■ Lug Nuts 73 SUSPENSION SYSTEM

Summary 77 COMPONENTS AND Review Questions 77 Chapter Quiz 77 OPERATION 117 ■■ Learning Objectives 117 ■■ Key Terms 117 chapter 5 ■■ Introduction 117 ■■ Frame Construction 117 TIRE-PRESSURE MONITORING ■■ Platforms 119 SYSTEMS 78 ■■ Unsprung Weight 119 ■■ ■■ Learning Objectives 78 Types of Suspensions 119 ■■ Hooke’s Law 120 ■■ Key Terms 78 ■■ Coil Springs 120 ■■ Need for Tire Pressure ■■ Leaf Springs 124 Monitoring 78 ■■ Torsion Bars 127 ■■ Tread Act 80 ■■ Suspension Principles 127 ■■ Indirect TPMS 80 ■■ Steering Knuckles 129 ■■ Direct TPMS 81 ■■ Control Arms 130 ■■ TPMS Pressure Sensors 82 ■■ Ball Joints 130 ■■ TPMS Sensor Operation 83 ■■ Strut Rods 131 ■■ TPMS Receiver 84 ■■ Stabilizer Bars 133 ■■ TPMS Diagnosis 85 ■■ Shock Absorbers 133 ■■ TPMS Sensor Activations 86 ■■ Struts 136 ■■ TPMS Diagnostic Tools 86 ■■ Bump Stops 136 ■■ Sensor Replacement Options 87 ■■ TPMS Sensor Relearn 88 Summary 141 ■■ TPMS Sensor Service Tools 89 Review Questions 141 Chapter Quiz 141 Summary 90 Review Questions 91 Chapter Quiz 91 chapter 8 FRONT SUSPENSION AND chapter 6 SERVICE 142 TIRE AND WHEEL SERVICE 92 ■■ Learning Objectives 142 ■■ Learning Objectives 92 ■■ Key Terms 142 ■■ Key Terms 92 ■■ Front Suspension Types 142 ■■ Tire Service and Proper Inflation 92 ■■ Short-/Long-Arm Suspensions 143 ■■ Nitrogen Inflation 93 ■■ Strut Suspension 145 ■■ Tire Inspection 94 ■■ Servicing the Suspension ■■ Wheel Removal/Installation 95 System 146 ■■ Tire Rotation 97 ■■ Road Test Diagnosis 146 ■■ Radial Runout 98 ■■ Dry Park Test (Suspension) 148 ■■ Lateral Runout 99 ■■ Visual Inspection 149

CONTENTS v

A01_HALD4642_08_SE_FM.indd 5 13/11/19 5:08 PM ■■ Ball Joints 150 chapter 11 ■■ Kingpin Diagnosis and Service 156 ■■ Shock Absorbers and Struts 156 ELECTRONIC STABILITY ■■ MacPherson Strut Replacement 158 ■■ Stabilizer Bar Links and Bushings 160 CONTROL SYSTEMS 201 ■■ Strut Rod Bushings 160 ■■ Learning Objectives 201 ■■ Front Coil Springs 161 ■■ Key Terms 201 ■■ Steering Knuckles 163 ■■ The Need for Electronic Stability ■■ Torsion Bars 164 Control 201 ■■ Control Arm Bushings 164 ■■ Federal Motor Vehicle Safety Standard

Summary 170 (FMVSS) No. 126 202 ■■ Review Questions 170 Sine with Dwell Test 202 ■■ Chapter Quiz 170 ESC Sensors 204 ■■ Traction Control 205 ■■ chapter 9 ESC/TC Diagnosis 208 Summary 208 REAR SUSPENSION AND Review Questions 209 SERVICE 172 Chapter Quiz 209 ■■ Learning Objectives 172 chapter 12 ■■ Key Terms 172 ■■ Solid Rear 172 STEERING COLUMNS AND ■■ Rear Suspensions 173 ■■ Trailing Arm Rear Suspensions 174 GEARS 210 ■■ Semi-Trailing Arm Rear Suspensions 175 ■■ Learning Objectives 210 ■■ Independent Rear Suspensions 175 ■■ Key Terms 210 ■■ Semi-Independent Rear Suspensions 176 ■■ Steering Wheels 210 ■■ Rear Suspension Service 176 ■■ Steering Wheel Removal 211 ■■ Rear Shock Replacement 177 ■■ Steering Columns 212 ■■ Rear Spring Replacement 179 ■■ Conventional Steering Gears 216 Summary 182 ■■ Recirculating Ball Steering Review Questions 182 Gear 219 Chapter Quiz 182 ■■ Steering Gear Adjustments 220 ■■ Rack-and-Pinion Steering Gear 222 chapter 10 ■■ Rack-and-Pinion Adjustments 225 Summary 226 ELECTRONIC SUSPENSION Review Questions 226 SYSTEMS 184 Chapter Quiz 226 ■■ Learning Objectives 184 ■■ Key Terms 184 chapter 13 ■■ The Need for Electronic Suspensions 184 ■■ Electronic Suspension Controls STEERING LINKAGE AND and Sensors 184 SERVICE 228 ■■ Electronic Suspension System ■■ Learning Objectives 228 Actuators 190 ■■ Key Terms 228 ■■ Types of Electronic Suspension 192 ■■ Steering Linkage 228 ■■ Automatic Level Control (ALC) 196 ■■ Rack-and-Pinion Inner Tie Rod Ends 229 ■■ Troubleshooting Rear Electronic Leveling ■■ Front Steer Versus Rear Steer 231 Systems 198 ■■ Four-Wheel Steering Systems 232 ■■ Magneto-Rheological (MR) ■■ Steering Linkage Lubrication 233 Suspension 198 ■■ Dry Park Test 234 Summary 200 ■■ Common Wear Items 236 Review Questions 200 ■■ Under-Vehicle Inspection 236 Chapter Quiz 200 ■■ Steering Linkage Replacement 238

vi CONTENTS

A01_HALD4642_08_SE_FM.indd 6 13/11/19 5:08 PM Summary 245 ■■ Rear Bearing and Seal Replacement 290 Review Questions 245 ■■ Bearing Failure Analysis 292 Chapter Quiz 245 Summary 297 Review Questions 297 chapter 14 Chapter Quiz 297 HYDRAULIC POWER STEERING chapter 17 SYSTEMS 246 ■■ Learning Objectives 246 DRIVESHAFTS AND CV ■■ Key Terms 246 JOINTS 299 ■■ Hydraulic Power Steering Systems 246 ■■ Learning Objectives 299 ■■ Power Steering Pump and Reservoir 247 ■■ Integral Power Steering 250 ■■ Key Terms 299 ■■ Variable-Effort Steering 254 ■■ DriveShafts 299 ■■ Power Steering Diagnosis 259 ■■ Driveshaft Balance 299 ■■ Power Steering Fluid 260 ■■ U-Joint Design and Operation 300 ■■ Double-Cardan Joints 303 Summary 269 ■■ Constant Velocity Joints 303 Review Questions 269 Chapter Quiz 269 Summary 308 Review Questions 308 Chapter Quiz 308 chapter 15 ELECTRIC POWER STEERING chapter 18 SYSTEMS 271 DRIVESHAFT AND CV JOINT ■■ Learning Objectives 271 ■■ Key Terms 271 SERVICE 310 ■■ ■■ Electric Power Steering Overview 271 Learning Objectives 310 ■■ EPS System Parts and Operation 272 ■■ Key Terms 310 ■■ Steering Shaft Sensor 275 ■■ U-Joint Diagnosis 310 ■■ Steering Wheel Position Sensor 275 ■■ Driveshaft and U-Joint Inspection 311 ■■ Power Steering Motor 275 ■■ U-Joint Replacement 312 ■■ Power Steering Control Module (PSCM) 275 ■■ U-Joint Working Angles 314 ■■ EPS Diagnosis 276 ■■ CV Joint Diagnosis 315 ■■ Self-Parking System 276 ■■ Replacement Shaft Assemblies 315 ■■ Electrohydraulic Power Steering 277 ■■ CV Joint Service 316

Summary 278 Summary 323 Review Questions 278 Review Questions 323 Chapter Quiz 278 Chapter Quiz 323

chapter 16 chapter 19 WHEEL BEARINGS AND WHEEL ALIGNMENT SERVICE 280 PRINCIPLES 324 ■■ Learning Objectives 280 ■■ Learning Objectives 324 ■■ Key Terms 280 ■■ Key Terms 324 ■■ Antifriction Bearings 280 ■■ Definition of a Wheel Alignment 324 ■■ Bearing Greases 283 ■■ Alignment-Related Problems 324 ■■ Seals 284 ■■ Camber 325 ■■ Bearing Diagnosis 284 ■■ Caster 327 ■■ Wheel Bearing Service 285 ■■ 330 ■■ Sealed Bearing Replacement 289 ■■ Steering Axis Inclination 333 ■■ Rear Drive Axle Classifications 289 ■■ Included Angle 334

CONTENTS vii

A01_HALD4642_08_SE_FM.indd 7 13/11/19 5:08 PM ■■ Scrub Radius 334 ■■ Hidden Structural Damage Diagnosis 364 ■■ Turning Radius (Toe-Out on Turns) 336 ■■ Reset Steering Angle Sensor (SAS) 364 ■■ Setback 337 Summary 370 ■■ Thrust Angle 337 Review Questions 370 ■■ Tracking 338 Chapter Quiz 370 ■■ Four-Wheel Alignment 338

Summary 339 Review Questions 339 chapter 21 Chapter Quiz 339 VIBRATION AND NOISE chapter 20 DIAGNOSIS AND CORRECTION 372 ALIGNMENT DIAGNOSIS AND ■■ Learning Objectives 372 ■■ Key Terms 372 SERVICE 340 ■■ Causes of Vibration and Noise 372 ■■ Learning Objectives 340 ■■ Test-Drive 373 ■■ Key Terms 340 ■■ Neutral Run-Up Test 375 ■■ Purpose of an Alignment 340 ■■ Vibration During Braking 375 ■■ Prealignment Correction Techniques 340 ■■ Vibration Speed Ranges 375 ■■ Prealignment Checks 340 ■■ Vibration Frequency 378 ■■ Lead/Pull 342 ■■ Correcting Driveline Angles 380 ■■ Memory Steer 343 ■■ Checking Driveshaft Runout 380 ■■ Torque Steer 343 ■■ Measuring Driveshaft U-Joint Phasing 380 ■■ Alignment Specifications 345 ■■ Checking Companion Flange Runout 380 ■■ Alignment Setup Procedures 346 ■■ Balancing the Driveshaft 381 ■■ Measuring Camber, Caster, SAI, Toe, ■■ Noise Diagnosis 381 and TOOT 347 ■■ Noise Correction 382 ■■ Specifications Versus Alignment Readings 348 Summary 385 ■■ Checking for Bent Struts, Spindles, or Control Review Questions 385 Arms 348 Chapter Quiz 385 ■■ Checking Frame Alignment of Front-Wheel-Drive Vehicles 349 ■■ Types of Alignments 350 appendix 1 ■■ Adjusting Rear Camber 353 SAMPLE SUSPENSION AND STEERING (A4) ASE-TYPE ■■ Guidelines for Adjusting Front Camber/SAI and Included Angle 354 CERTIFICATION TEST 386 ■■ Front Camber/Caster Adjustment Methods 355 appendix 2 ■■ Adjusting Front Camber/Caster 356 2017 ASE CORRELATION CHART 390 ■■ Setting Toe 356 ■■ Centering the Steering Wheel 358 ■■ Tolerance Adjustment Procedure 359 GLOSSARY 394 ■■ Aligning Electronic-Suspension Vehicles 360 ■■ Aligning Modified Vehicles 361 INDEX 404

viii CONTENTS

A01_HALD4642_08_SE_FM.indd 8 13/11/19 5:08 PM PREFACE

PROFESSIONAL TECHNICIAN SERIES Part of Pearson ASE CORRELATED This comprehensive textbook is divid- Automotive’s Series, the eighth edition of Automotive Steering, ed into sections that correspond to the A4 area of certifications Suspension, and Alignment represents the future of automotive as specified by the National Institute for Automotive Service textbooks. The series is a full-color, media-integrated solution for Excellence (ASE). The areas of the ASE material certification today’s students and instructors. The series includes textbooks test are listed in the objectives at the beginning of each chap- that cover all eight areas of ASE certification, plus additional titles ter, and all laboratory worksheets are correlated to the ASE covering common courses. Task Sheets. The series is also peer reviewed for technical accuracy.

NEW THIS EDITION Based on the suggestions and rec- A COMPLETE INSTRUCTOR AND STUDENT SUPPLE- ommendations from automotive instructors and reviewers, MENTS PACKAGE All Professional Technician textbooks the following changes have been made to the eighth edition: are accompanied by a full set of instructor and student supple- ments. Please see page xii for a detailed list of supplements. "" 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 A FOCUS ON DIAGNOSIS AND PROBLEM SOLVING Vehicle Identification. The Professional Technician Series has been developed to "" Over 40 new full-color photos and line drawings to make satisfy the need for a greater emphasis on problem diag- the subject come alive. nosis. Automotive instructors and service managers agree that students and beginning technicians need more training "" Updated throughout and correlated to the latest ASE A4 in diagnostic procedures and skill development. To meet tasks. this need and demonstrate how real-world problems are "" New Case Studies included in this edition covering the solved, “Case Study” features are included throughout “three Cs” (Complaint, Cause, and Correction). and highlight how real-life problems are diagnosed and re- "" New OSHA hazardous chemical labeling requirements paired. added to Chapter 2. The following pages highlight the unique core features "" Additional content on snap-in and clamp-on TPMS sensors, that set the Pearson Automotive Series book apart from other plus updated relearn procedures, in chapter 5. automotive textbooks.

ix

A01_HALD4642_08_SE_FM.indd 9 13/11/19 5:08 PM IN-TEXT FEATURES

SAFETY TIP

chapter SERVICE INFORMATION, Shop Cloth Disposal WORK ORDERS, AND Always dispose of oily shop cloths in an enclosed 1 VEHICLE IDENTIFICATION container to prevent a fire. ● SEE FIGURE 2–63. Whenever oily cloths are thrown together on the floor

LEARNING OBJECTIVES: After studying this chapter, the reader should be able to: or workbench, a chemical reaction can occur, which Discuss the importance of vehicle owner’s manuals, service Explain vehicle identification, vehicle safety certification label, records, and service information. and the VECI label. can ignite the cloth even without an open flame. This Explain the different types of service information. Discuss the different types of emission standards. Describe vehicle recalls and campaigns. Explain calibration codes and casting numbers. Discuss the importance of the work order. This chapter will help prepare for the Suspension and Steering process of ignition without an open flame is called Explain why service records are important. (A4) and (A5) ASE certification test. Discuss the parts of a vehicle, and differentiate between front-wheel drive and rear-wheel drive. spontaneous combustion.

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

OWNER’S MANUALS SAFETY TIPS alert students to possible hazards on the job CONTENT The owner’s manual is the instructional booklet and how to avoid them. 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 CASE STUDY 5. Maintenance schedule for all fluids, including coolant, brake fluid, fluid, and differential fluid 6. How to program the remote control, as well as the power windows and door locks FIGURE 1–1 The owner’s manual has a lot of information 7. How to reset the tire pressure monitoring system (TPMS) pertaining to the operation, as well as the maintenance and The Rattle Story after a tire rotation SEE FIGURE 1–1. resetting procedures, that technicians often need. 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 SERVICE INFORMATION, WORK ORDERS, AND VEHICLE IDENTIFICATION 1 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, LEARNING OBJECTIVES AND KEY TERMS appear at whenever the right rear wheel was lifted, the noise the beginning of each chapter to help students and instruc- occurred. The problem was a worn (elongated) shock tors focus on the most important material in each chapter. absorber mounting hole. A washer with the proper- The chapter objectives are based on specific ASE and NATEF size hole was welded over the worn lower frame tasks. mount and the was bolted back into place. Summary: ■■ Complaint—Vehicle owner complained of a rattle TECH TIP sound from the rear suspension at times. ■■ Cause—The lower shock mount was found to be It Just Takes a Second worn (elongated) causing the noise. ■■ Correction—A steel washer was welded over the Whenever removing any automotive component, it is worn lower frame mount which restored the shock wise to screw the bolts back into the holes a couple mount to the correct size and solved the noise of threads by hand. This ensures that the right bolt issue. will be used in its original location when the compo- nent or part is put back on the vehicle.

CASE STUDIES present students with actual automotive scenarios and shows how these common (and sometimes feature real-world advice and “tricks of the TECH TIPS ­uncommon) problems were diagnosed and repaired. trade” from ASE-certified master technicians.

x IN-TEXT FEATURES

A01_HALD4642_08_SE_FM.indd 10 13/11/19 5:08 PM ? FREQUENTLY ASKED QUESTION WARNING

How Many Types of Screw Heads Are Used in Do not use incandescent trouble lights around Automotive Applications? gasoline or other flammable liquids. The liquids There are many, including Torx, hex (also called can cause the bulb to break and the hot filament Allen), plus many others used in custom vans and can ignite the flammable liquid which can cause motor homes. ● SEE FIGURE 1–9. ­personal injury or even death.

FREQUENTLY ASKED QUESTIONS are based on the WARNINGS alert students to potential dangers to them- author’s own experience and provide answers to many of the selves during a specific task or service procedure. most common questions asked by students and beginning ser- vice technicians.

SUMMARY

1. Bolts, studs, and nuts are commonly used as fasteners 7. Torque wrenches measure the amount of torque applied NOTE: Most of these “locking nuts” are grouped in the . The sizes for fractional and metric threads to a fastener. are different and are not interchangeable. The grade is the 8. Screwdriver types include straight blade (flat tip) and rating of the strength of a fastener. Phillips. together and are commonly referred to as prevail- 2. Whenever a vehicle is raised above the ground, it must 9. Hammers and mallets come in a variety of sizes and be supported at a substantial section of the body or weights. frame. ing torque nuts. This means that the nut will hold its 10. Pliers are a useful tool and are available in many different 3. Wrenches are available in open end, box end, and combi- types, including slip-joint, multigroove, linesman’s, diago- nation open and box end. nal, needle-nose, and locking pliers. tightness or torque and not loosen with movement or 4. An adjustable wrench should only be used where the 11. Other common hand tools include snap-ring pliers, files, proper size is not available. cutters, punches, chisels, and hacksaws. 5. Line wrenches are also called flare-nut wrenches, fitting 12. Hybrid electric vehicles should be de-powered if any of vibration. wrenches, or tube-nut wrenches and are used to remove the high-voltage components are going to be serviced. fuel or refrigerant lines. 6. Sockets are rotated by a ratchet or breaker bar, also called a flex handle. NOTES provide students with additional technical informa- tion to give them a greater understanding of a specific task or REVIEW QUESTIONS procedure. 1. Why are wrenches offset 15 degrees? 4. Which type of screwdriver requires the use of a hammer 2. What are the other names for a line wrench? or mallet? 3. What are the standard automotive drive sizes for sockets? 5. What is inside a dead-blow hammer?

CHAPTER QUIZ

1. The correct location for the pads when hoisting or jacking 5. Wrenches are made from ______. CAUTION: Never use hardware store (nongraded) the vehicle can often be found in the ______. a. cast from nickel steel a. service manual c. owner’s manual b. forged alloy steel b. shop manual d. all of the above c. machined from billet steel bolts, studs, or nuts on any vehicle steering, suspen- 2. For the best working position, the work should be d. cast from chrome steel ______. 6. The proper term for Channel Locks is ______. sion, or brake component. Always use the exact size a. at neck or head level a. Vise Grips b. at knee or ankle level b. crescent wrench c. overhead by about 1 foot c. locking pliers and grade of hardware that is specified and used by d. at chest or elbow level d. multigroove adjustable pliers 3. A high-strength bolt is identified by ______. 7. The proper term for Vise Grips is ______. a. a UNC symbol a. locking pliers the vehicle manufacturer. b. lines on the head b. slip-joint pliers c. strength letter codes c. side cuts d. the coarse threads d. multigroove adjustable pliers 4. A fastener that uses threads on both ends is called a ______. a. cap screw c. machine screw CAUTIONS alert students about potential damage to b. stud d. crest fastener the vehicle that can occur during a specific task or service

­procedure. 40 CHAPTER 2

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.

IN-TEXT FEATURES xi

A01_HALD4642_08_SE_FM.indd 11 13/11/19 5:08 PM HOISTING THE VEHICLE STEP BY STEP

The first step in hoisting a vehicle is to properly align Most vehicles will be correctly positioned when the Position the pads under the vehicle under the After being sure all pads are correctly positioned, the vehicle in the center of the stall. left front tire is centered on the tire pad. recommended locations. use the electromechanical controls to raise the 1 2 7 8 vehicle.

With the vehicle raised 1 foot (30 cm) off the ground, If raising a vehicle without a frame, place the The arms can be moved in and out and most pads Most lifts are equipped with short pad extensions push down on the vehicle to check to see if it is stable flat pads under the pinch weld seam to spread that are often necessary to use to allow the pad to on the pads. If the vehicle rocks, lower the vehicle 10 the load. If additional clearance is necessary, can be rotated to allow for many different types of 9 3 vehicle construction. 4 contact the frame of a vehicle without causing the and reset the pads. The vehicle can be raised to any the pads can be raised as shown. arm of the lift to hit and damage parts of the body. desired working level. Be sure the safety is engaged before working on or under the vehicle.

Tall pad extensions can also be used to gain access An additional extension may be necessary to hoist a When the service work is completed, the After lowering the vehicle, be sure all arms STEP-BY-STEP photo sequences to the frame of a vehicle. This position is needed to truck or van equipped with running boards to give the hoist should be raised slightly and the safety of the lift are moved out of the way before 5 safely hoist many pickup trucks, vans, and sport util- 6 necessary clearance. 11 released before using the hydraulic lever to 12 driving the vehicle out of the work stall. ity vehicles. lower the vehicle. show in detail the steps involved in performing a specific task or service 38 CHAPTER2 TOOLS AND SAFETY 39 procedure.

SUPPLEMENTS

RESOURCES IN PRINT AND ONLINE Automotive Steering, Suspension, and Alignment NAME OF SUPPLEMENT PRINT ONLINE AUDIENCE DESCRIPTION Instructor ✔ Instructors NEW! The ultimate teaching aid: chapter Resource Manual summaries, key terms, chapter learning 0135674581 objectives, and lecture resources TestGen ✔ Instructors Test generation software and test bank for 0135674530 the text. PowerPoint ✔ Instructors Slides include chapter learning objectives, Presentation lecture outline of the text, and graphics from 013575836X the book. Image Bank ✔ Instructors All of the images and graphs from the 0135758424 textbook to create customized lecture slides. ASE Correlated ✔ Instructors Downloadable ASE task sheets for easy Task Sheets – for customization and development of unique Instructors task sheets. 0135674638 ASE Correlated ✔ Students Study activity manual that correlates ASE Task Sheets – For Automobile Standards to chapters and page Students numbers in the text. Available to students at a 0135758416 discounted price when packaged with the text. VitalSource eBook ✔ Students An alternative to purchasing the print 0135674581 ­textbook, students can save up to 50% off the ­suggested list price of the print text. Visit www.vitalsource.com 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.

xii SUPPLEMENTS

A01_HALD4642_08_SE_FM.indd 12 13/11/19 5:08 PM ACKNOWLEDGMENTS

A large number of people and organizations have cooperated in Tony Martin providing the reference material and technical information used in University of Alaska Southeast this text. The author wishes to express sincere thanks to the fol- Kerry Meier lowing individuals and organizations for their special contributions: San Juan College Steve Cartwright—Federal-Mogul Jim Morton Brad Halderman—Hankook Tires Automotive Training Center (ATC) Joe Palazzolo—GKN Driveline Fritz Peacock Dave Fox—Hunter Engineering Indiana Vocational Technical College Carl Borsani—Graphic Home Dennis Peter NAIT (Canada) TECHNICAL AND CONTENT REVIEWERS The following Greg Pfahl people reviewed the manuscript before production and checked Miami-Jacobs Career College it for technical accuracy and clarity of presentation. Their sug- gestions and recommendations were included in the final draft Steve Polley of the manuscript. Their input helped make this textbook clear Pittsburgh State University and technically accurate while maintaining the easy-to-read style Kenneth Redick that has made other books from the same author so popular. Hudson Valley Community College Jeff Rehkopf Jim Anderson Florida State College Greenville High School Mark Spisak Victor Bridges Central Piedmont Community College Umpqua Community College Chuck Taylor Dr. Roger Donovan Sinclair Community College Illinois Central College Walter Varella A. C. Durdin Trident Technical College Moraine Park Technical College Mitchell Walker Al Engledahl St. Louis Community College at Forest Park College of Dupage Jennifer Wise Orlando Grijalva Sinclair Community College Tarrant County College, South Larry Hagelberger Special thanks to instructional designer Upper Valley Joint Vocational School Alexis Skriloff James. Oldrick Hajzler Red River College Betsy Hoffman PHOTO SEQUENCES The author wishes to thank Brad Vermont Technical College ­Halderman, Alyssa Williams, Carl Borsani, plus Chuck Taylor of Sinclair Community College in Dayton, Ohio, plus Steve Richard Krieger ­Cartwright who helped with many of the photos. Special Michigan Institute of Technology thanks to Dick Krieger and Jeff Rehkopf for their detailed and Steven T. Lee thorough review of the manuscript before publication and to Lincoln Technical Institute Richard Reaves for all of his help. Carlton H. Mabe, Sr. Virginia Western Community College Most of all, I wish to thank Michelle Halderman for her Roy Marks assistance in all phases of manuscript preparation. Owens Community College —James D. Halderman

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A01_HALD4642_08_SE_FM.indd 13 13/11/19 5:08 PM 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 [email protected]

xiv ABOUT THE AUTHOR

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