Course Outline

Fundamentals of Automotive Steering and Suspension Systems Training Outline

Course Title: Fundamentals of Automotive Steering and Suspension Systems

Duration: 2 Weeks (Monday – Friday)

Target Audience: Apprentice auto technicians, mechanics seeking skill updates, or individuals wanting a comprehensive understanding of these critical vehicle systems.

Week 1: Suspension Systems and Wheel Alignment Fundamentals

  • Day 1: Introduction, Safety, and Basic Concepts
    • Morning (Theory):
      • Course Introduction: Objectives and Schedule.
      • Workshop Safety: Lifting vehicles (hoists, jacks, stands), tool safety, personal protective equipment (PPE).
      • Purpose of Suspension Systems: Ride Comfort, Handling, Keeping Tires in Contact with Road.
      • Purpose of Steering Systems: Directional Control.
      • Basic Terminology: Sprung vs. Unsprung Weight, Jounce/Rebound.
      • Introduction to Essential Tools: Hand tools, torque wrenches, specialty suspension/steering tools.
    • Afternoon (Practical):
      • Safe vehicle lifting procedures demonstration and practice.
      • Identification of major steering and suspension components on various vehicles.
      • Proper use and care of basic hand tools.
  • Day 2: Suspension Components: Springs and Dampers
    • Morning (Theory):
      • Types of Springs: Coil Springs, Leaf Springs, Torsion Bars, Air Springs – Construction and Operation.
      • Role of Dampers (Shock Absorbers & Struts): Controlling Oscillations, Types (Twin-tube, Monotube, Gas-charged).
      • MacPherson Struts vs. Shock Absorbers: Key differences.
    • Afternoon (Practical):
      • Inspection of various spring types for damage or fatigue.
      • Inspection of shock absorbers and struts for leaks and damage.
      • Bounce test demonstration and interpretation.
      • Demonstration: Safe removal and installation of a coil spring (using spring compressor) and a shock absorber/strut assembly.
  • Day 3: Suspension Components: Linkage and Connections
    • Morning (Theory):
      • Control Arms (Wishbones): Purpose, Types (Upper/Lower), Construction.
      • Ball Joints: Function, Types (Load-carrying vs. Follower), Wear Indicators.
      • Bushings: Purpose (Isolation, Pivot Points), Types (Rubber, Polyurethane), Wear Symptoms.
      • Stabilizer Bars (Anti-Roll Bars) and Links: Function (Reducing Body Roll), Components.
    • Afternoon (Practical):
      • Inspecting control arms for bends or damage.
      • Checking ball joints for wear (play) using various methods.
      • Inspecting bushings for cracks, deterioration, or looseness.
      • Inspecting stabilizer bar links and bushings.
  • Day 4: Suspension System Designs
    • Morning (Theory):
      • Dependent Suspension (Solid Axle): Design (Leaf Spring, Coil Spring with Links), Advantages/Disadvantages.
      • Independent Suspension: Principles, Advantages/Disadvantages.
      • Common Independent Designs:
        • MacPherson Strut: Components and Operation.
        • Double Wishbone (SLA – Short/Long Arm): Components and Operation.
        • Multi-Link Suspension: Concept and Variations.
    • Afternoon (Practical):
      • Identifying different suspension types on training vehicles.
      • Tracing load paths and identifying key pivot points.
      • Discussion on how design affects handling and ride comfort.
  • Day 5: Wheel Alignment Theory
    • Morning (Theory):
      • Importance of Wheel Alignment: Tire Wear, Handling, Fuel Economy, Safety.
      • Key Alignment Angles:
        • Camber: Definition, Positive/Negative, Effects.
        • Caster: Definition, Positive/Negative, Effects (Steering Returnability, Stability).
        • Toe: Definition (Toe-in/Toe-out), Effects (Tire Wear, Stability).
        • Steering Axis Inclination (SAI) & Included Angle: Definition and Diagnostic Value.
        • Thrust Angle & Setback.
    • Afternoon (Practical/Demo):
      • Introduction to Wheel Alignment Equipment (Laser/CCD/3D).
      • Performing pre-alignment inspection (Tire pressure, ride height, suspension/steering component check).
      • Demonstration: Mounting alignment heads and obtaining initial readings.

Week 2: Steering Systems and Diagnostics

  • Day 6: Steering System Components and Manual Steering
    • Morning (Theory):
      • Steering System Layout: Steering Wheel, Column (Collapsible, Tilt/Telescope), Intermediate Shaft (U-Joints), Steering Gear.
      • Types of Steering Gears:
        • Rack and Pinion: Components (Rack, Pinion, Inner/Outer Tie Rods, Bellows), Operation.
        • Recirculating Ball (Steering Box): Components (Worm Gear, Sector Shaft, Pitman Arm, Idler Arm, Center Link), Operation.
      • Manual Steering Operation and Feel.
    • Afternoon (Practical):
      • Identifying steering components on different vehicles.
      • Inspecting steering linkage for wear (Tie rod ends, ball joints, idler/pitman arms).
      • Checking steering free play.
      • Inspecting steering rack bellows/boots for damage.
  • Day 7: Hydraulic Power Steering (HPS)
    • Morning (Theory):
      • Principles of Hydraulic Assist.
      • Components: Power Steering Pump (Vane/Roller Type), Reservoir, High/Low-Pressure Hoses, Power Steering Fluid, Control Valve (Rotary/Spool), Power Piston (in Rack or Box).
      • System Operation: How assist is generated based on steering input.
      • Variable Assist Systems (Speed-sensitive).
    • Afternoon (Practical):
      • Inspecting HPS components for leaks (Pump, hoses, gear).
      • Checking power steering fluid level and condition.
      • Demonstration: Power steering pressure testing (basic).
      • Bleeding procedures for hydraulic systems.
  • Day 8: Electric Power Steering (EPS)
    • Morning (Theory):
      • Advantages of EPS (Fuel Economy, Tunability, Integration with ADAS).
      • Types of EPS:
        • Column Assist (C-EPS): Motor assists the steering column.
        • Pinion Assist (P-EPS): Motor assists the pinion gear.
        • Rack Assist (R-EPS): Motor directly assists the steering rack.
      • Key Components: Electric Motor, Torque Sensor, Control Module, Reduction Gear.
      • Basic Operation: How torque sensor input leads to motor assist.
    • Afternoon (Practical/Demo):
      • Identifying EPS components on vehicles.
      • Understanding EPS warning lights.
      • Using a Scan Tool to check EPS module for codes and basic data (Torque sensor readings – requires capable tool).
      • Discussion on safety precautions with EPS systems.
  • Day 9: Steering and Suspension Diagnostics
    • Morning (Theory):
      • Common Customer Complaints: Noise (Clunking, Squeaking, Whining), Pulling/Drifting, Hard Steering, Vibration/Shimmy, Poor Returnability, Excessive Play.
      • Systematic Diagnostic Approach: Verify Complaint -> Visual Inspection -> Check Basics (Tires, Fluid) -> Test Drive -> Component Testing/Isolation.
      • Relating Alignment Angles to Handling Problems and Tire Wear Patterns.
      • Diagnosing Power Steering Issues (Hydraulic vs. Electric).
    • Afternoon (Practical):
      • Practical diagnosis scenarios (simulated faults if possible).
      • Using pry bars and visual inspection to find worn components.
      • Interpreting tire wear patterns.
      • Group troubleshooting exercises.
  • Day 10: Wheel Alignment Practical and Modern Systems Integration
    • Morning (Practical):
      • Hands-on Wheel Alignment Practice: Setting up machine, obtaining readings, interpreting results.
      • Making Adjustments: Demonstrating and practicing common adjustments (Toe, Camber, Caster where possible).
      • Understanding when alignment is necessary (after component replacement, impacts, tire wear).
    • Afternoon (Theory/Review):
      • Brief overview of Steering/Suspension interaction with ADAS (Advanced Driver-Assistance Systems) – Lane Keeping Assist, Automated Parking (concept of calibration).
      • Review of Key Concepts from both weeks.
      • Q&A Session.
      • Final Assessment (Written Quiz or Practical Evaluation).
      • Course feedback and closing.