1. © 2012 Delmar, Cengage Learning Suspension System Service Chapter 64

2. © 2012 Delmar, Cengage Learning Objectives Diagnose suspension system problems Service suspension system components Describe suspension system repairs Replace Macpherson struts Replace suspension bushings

3. © 2012 Delmar, Cengage Learning Introduction This chapter emphasizes the diagnosis and service of suspension system parts –Commonly performed chassis diagnosis and repair procedures Suspension parts in good condition and properly aligned are subjected to two forces –Car weight on springs and road force of on tires Suspension parts take a large amount of abuse –Forces transmitted through the suspension parts cause wear over time

4. © 2012 Delmar, Cengage Learning Diagnosing Suspension System Problems Considerations –Carefully question a customer about symptoms –Entire system IS affected when one part becomes worn –Spring sag is normal and occurs with the passage of time –Check all ball joints and bushings for looseness

5. © 2012 Delmar, Cengage Learning Shock Absorber Service Shock absorbers can be functioning poorly before obvious signs of failure –Defective shock absorber can cause tire “hop” –Shock can be defective because it is leaking or physically damaged –Some OE shock absorbers will still work well after 50,000 miles

6. © 2012 Delmar, Cengage Learning Testing a Shock Perform a visual inspection of the shock –Inspect shock mounts and rubber cushions –Check for fluid leaks –Outside of shock is damaged: replace both shocks –Rubber bump stops show signs of contact: shock could be damaged –Check shock mounts –Air shock: sometimes fail when it gets a hole in its rubber bladder –Gas shock has lost its gas charge: no longer will expand

7. © 2012 Delmar, Cengage Learning Macpherson Strut Service Macpherson strut shock fails –Common repair procedures Replace entire assembly Install a strut cartridge Some struts are easily removed at the bottom by removing two bolts –Spring compressor is used to compress the coil spring –Some struts can be serviced with a shock cartridge

8. © 2012 Delmar, Cengage Learning Inspect the Upper Strut Bearing and Install the Coil Spring Inspect the upper strut bearing –Inspect condition of upper strut bearing while strut is disassembled Install the coil spring –Install coil spring and tighten locknut –Be sure both ends of spring are correctly seated before removing compressor

9. © 2012 Delmar, Cengage Learning Reinstall the Strut Assembly Reinstall in same position as before –Wheel alignment may be needed after strut replacement –Brakes will need to be bled if brake caliper was disconnected

10. © 2012 Delmar, Cengage Learning Suspension Bushing Service Bushing characteristics –Made of synthetic rubber –Prone to heat damage –Should not be lubricated –Deteriorate with age –Removed by pressing or driving them out

11. © 2012 Delmar, Cengage Learning Strut Rod Bushing Service and Stabilizer Bar Service Strut rod bushing service –Remove the fasteners –Most bushings have a center spacer Stabilizer bar service –Inspect bushings at both ends of stabilizer bar –Replace any bushings that are cracked, worn, or weathered

12. © 2012 Delmar, Cengage Learning Spindle Service Replace a steering knuckle or spindle that is damaged –If a wheel bearing fails it can wear or heat the spindle Changes the metallurgy of the spindle and it must be replaced Damage from a collision will be noticed during SAI alignment angle check

13. © 2012 Delmar, Cengage Learning Ball Joint Service Important points and considerations –Ball joints are relatively trouble-free –Feel around outside of boot and look for tears –Always check specifications –Load-carrying ball joint usually has some movement when unloaded –Determine whether ball joint is a load carrier or follower

14. © 2012 Delmar, Cengage Learning Measuring Ball Joint Wear Important points and considerations –Check manufacturer's recommended procedures before checking ball joints –For an accurate check: ball joint must not support weight of vehicle –Follower joint should be checked at same time loaded ball joint is unloaded for testing To check follower ball joint for movement: unload joint and try to move tire back and forth –Some ball joints have wear indicators

15. © 2012 Delmar, Cengage Learning Separating Tapered Connections Loosening the tapered connection on a ball joint can be accomplished using a large hammer –Remove cotton pin from ball joint nut and loosen nut –Position vehicle so coil spring is pushing control arm away from ball joint –Use hammer to pound sharply on steering knuckle on outside of taper

16. © 2012 Delmar, Cengage Learning Replacing a Ball Joint Characteristics –Some original equipment ball joints are fastened to control arm with rivets –Ball joints can also be pressed or threaded into hole in control arm –Some pressed-fit ball joints have a spot weld that hold them in place

17. © 2012 Delmar, Cengage Learning

18. Coil Spring Service Characteristics –Coil spring will rarely break unless it has been constantly overloaded or has a stress raiser –Incorrect ride height affects wheel alignment angles, camber, toe, SAI, and scrub radius –A vehicle that is too low cannot be aligned properly

19. © 2012 Delmar, Cengage Learning Adjusting Spring Height and Coil Spring Replacement Adjusting spring height –Correct ride height must be restored prior to alignment –Coil springs must be replaced when they have sagged beyond specifications Coil spring replacement –Replaced in front or rear pairs –Replacement springs must be of the same kind

20. © 2012 Delmar, Cengage Learning SLA Coil Spring Replacement Major considerations –During a coil spring replacement: only lower ball joint needs to be removed –Spring seats must be accurately aligned –Torsion bar adjusting bolt must be loosened before removing torsion bar –Leaf spring problems include broken leaves, spring sag, and differences in ride height

21. © 2012 Delmar, Cengage Learning Wheel Alignment Required after suspension repairs –Repositions suspension components Car will be safe to drive and will go straight without unusual tire wear Remember to torque bolts that go through bushings only after vehicle is resting on its tires

22. © 2012 Delmar, Cengage Learning Electronic Suspension Service Electronic suspension system problems –Often related to mechanical failures –Electrical failures can also occur in the air system Wiring connections –Common source of problems Electronic failures –Set a diagnostic trouble code and cause instrument panel light to flash Electronic suspension systems –Several sensors

23. © 2012 Delmar, Cengage Learning Electronically Controlled Shock Absorbers Some shock absorbers are electronically controlled –Remove actuator: squeeze plastic retainers to lift motor from top of strut Diagnosing actuator system –Wiring color codes and specific instructions required