Steering and Suspension Diagnosis 33 - Steering and Suspension Systems Student Guide FCS14608REF FCS-14608-REF Course Code: 33S15T0 April, 2007 Ford Customer Service Division Technical Training IMPORTANT SAFETY NOTICE Appropriate service methods and proper repair procedures are essential for the safe, reliable operation of all motor vehicles, as well as the personal safety of the individual doing the work This manual provides general directions for accomplishing service and repair work with tested, effective techniques Following them will help assure reliability There are numerous variations in procedures, techniques, tools and parts for servicing vehicles, as well as in the skill of the individual doing the work This manual cannot possibly anticipate all such variations and provide advice or cautions as to each Accordingly, anyone who departs from instructions provided in this manual must first establish that he compromises neither his personal safety nor the vehicle integrity by his choice of methods, tools or parts As you read through the procedures, you will come across NOTES, CAUTIONS, and WARNINGS Each one is there for a specific purpose NOTES give you added information that will help you to complete a particular procedure CAUTIONS are given to prevent you from making an error that could damage the vehicle WARNINGS remind you to be especially careful in those areas where carelessness can cause personal injury The following list contains some general WARNINGS that you should follow when you work on a vehicle • • Always wear safety glasses for eye protection • • • To prevent serious burns, avoid contact with hot metal parts such as the radiator, exhaust manifold, tail pipe, catalytic converter and muffler Be sure that the ignition switch is always in the OFF position, unless otherwise required by the procedure • • Do not smoke while working on the vehicle Set the parking brake when working on the vehicle If you have an automatic transmission, set it in PARK unless instructed otherwise for a specific service operation If you have a manual transmission it should be in REVERSE (engine OFF) or NEUTRAL (engine ON) unless instructed otherwise for a specific service operation • Keep hands and other objects clear of the radiator fan blades Electric cooling fans can start to operate at any time by an increase in underhood temperatures, even though the ignition is in the OFF position Therefore, care should be taken to ensure that the electric cooling fan is completely disconnected when working under the hood Use safety stands whenever a procedure requires you to be under the vehicle • Operate the engine only in a well-ventilated area to avoid the danger of carbon monoxide • Keep yourself and your clothing away from moving parts when the engine is running, especially the fan and belts To avoid injury, always remove rings, watches, loose hanging jewelry, and loose clothing before beginning to work on a vehicle Tie long hair securely behind your head The recommendations and suggestions contained in this manual are made to assist the dealer in improving his dealership parts and/or service department operations These recommendations and suggestions not supersede or override the provisions of the Warranty and Policy Manual, and in any cases where there may be a conflict, the provisions of the Warranty and Policy Manual shall govern The descriptions, testing procedures, and specifications in this handbook were in effect at the time the handbook was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications, design, or testing procedures without notice and without incurring obligation Any reference to brand names in this manual is intended merely as an example of the types of tools, lubricants, materials, etc recommended for use Equivalents, if available, may be used The right is reserved to make changes at any time without notice WARNING: Many brake linings contain asbestos fibers When working on brake components, avoid breathing the dust Breathing the asbestos dust can cause asbestosis and cancer Breathing asbestos dust is harmful to your health Dust and dirt present on car wheel brake and clutch assemblies may contain asbestos fibers that are hazardous to your health when made airborne by cleaning with compressed air or by dry brushing Wheel brake assemblies and clutch facings should be cleaned using a vacuum cleaner recommended for use with asbestos fibers Dust and dirt should be disposed of in a manner that prevents dust exposure, such as sealed bags The bag must be labeled per OSHA instructions and the trash hauler notified as to the contents of the bag If a vacuum bag suitable for asbestos is not available, cleaning should be done wet If dust generation is still possible, technicians should wear government approved toxic dust purifying respirators OSHA requires areas where asbestos dust generation is possible to be isolated and posted with warning signs Only technicians concerned with performing brake or clutch service should be present in the area Copyright © 2006 Ford Motor Company Produced and Coordinated by Technical Service Support Operations Ford Customer Service Division April, 2007 M CUSTOMER EXPECTATIONS Customer Expectations: Service Make it convenient to have my vehicle serviced at your dealership The Service Advisor should demonstrate a genuine concern for my service needs Fix it right the first time, on time Complete servicing my vehicle in a timely and professional manner Provide me with a clear and thorough explanation of the service performed Call me within a reasonable amount of time after my service visit to ensure that I'm completely satisfied Be responsive to questions or concerns that I bring to your attention Expectation #3 “Fix It Right the First Time, on Time.” Both service advisors and technicians are important players when it comes to Expectation #3 Why Customers tell us “Fixing It Right the First Time, on Time” is one of the reasons they would decide to return to a dealer to buy a vehicle and get their vehicles serviced Technician Training It is our goal to help the technician acquire all of the skills and knowledge necessary to “Fix it Right the First Time, on Time.” We refer to this as “competency.” Technician’s Role Acquire the skills and knowledge for competency in your specialty via: STST New Model — Web-Based — Web-Based — Instructor Led — Instructor Led The Benefits The successful implementation of expectations means: — Satisfied customers — Repeat vehicle sales — Repeat service sales — Recognition that Ford and Lincoln/Mercury technicians are “the Best in the Business” STEERING AND SUSPENSION DIAGNOSIS TABLE OF CONTENTS INTRODUCTION INTRO - Steering and Suspension Diagnosis Intro - Course description Intro - Worksheets Intro - Course requirements Intro - Course objectives Intro - PREREQUISITE REVIEW - LESSON ONE WORKSTATIONS Lesson One – Workstation 1: Purging the powersteering system Lesson One – Workstation 2: Power steering diagnosis using CMT Lesson One – Workstation 3: Balljoint inspection Lesson One – Workstation 4: Suspension inspection - 13 - 14 - 16 - 18 - 21 INSTRUCTOR-LED DEMONSTRATION: RIDE HEIGHT CALIBRATION - LESSON TWO WORKSTATIONS - Lesson Two – Workstation 1: Rear air suspension diagnosis - Lesson Two – Workstation 2: Alignment concern using CMT - Lesson Two – Workstation 3: Air suspension diagnosis - 12 Lesson Two – Workstation 4: Component testing - 14 LESSON THREE WORKSTATIONS Lesson Three – Workstation 1: Steering system diagnosis Lesson Three – Workstation 2: Alignment concern using CMT Lesson Three – Workstation 3: Air suspension diagnosis Lesson Three – Workstation 4: Rear suspension concern 3-1 3-2 3-3 3-8 3-9 APPENDIX APPENDIX - Balljoint Job Aid APPENDIX - Steering and Suspension Diagnosis TOC - i April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis TOC - ii TABLE OF CONTENTS April, 2007 STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION INTRODUCTION Steering and Suspension Diagnosis Intro - April, 2007 STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION Steering and Suspension Diagnosis Course Description This is a 3-day course facilitated by an instructor This course is designed to provide hands-on opportunities for you to learn and improve your skills using tools and equipment and to apply knowledge learned in previous curriculum courses Each day you will have multiple opportunities to practice selected skills The results of your work are recorded on worksheets Worksheets All classroom and hands-on activities are guided by worksheets When you are assigned to one of four workstations, you will be given 30 to 45 minutes to complete the tasks and questions required by the worksheet for that workstation Every 30 to 45 minutes, you will move to another workstation and complete another worksheet until all four worksheets are complete Steering and Suspension Diagnosis Intro - April, 2007 STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION Course Requirements Each technician attending this course is required to pass a combination of hands-on and written evaluations These are administered on the afternoon of the fourth day z The hands-on evaluation is a pass/fail type It is conducted with exercises in steering and suspension diagnosis, and will cover: – Steering and/or suspension system diagnosis – Diagnostic tool usage – Service publication usage In order to pass the course, you must demonstrate mastery of the skills covered at the evaluated hands-on exercise AND you must answer at least 80% of the written post-test questions correctly Course Objectives Upon successful completion of this course, you will be able to: z Properly inspect and test steering and suspension system components z Correctly inspect ball joints and measure ball joint deflection z Correctly fill a power steering system after component replacement z Correctly purge air from the power steering system z Perform a simulated pump flow and pressure test using a power steering analyzer z Diagnose and correct excessive tire wear and pull concerns using a simulated alignment machine Steering and Suspension Diagnosis Intro - April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis Intro - INTRODUCTION April, 2007 LESSON THREE Steering and Suspension Diagnosis WORKSTATION 3-4 April, 2007 LESSON THREE WORKSTATION What repair procedures were performed to correct the concern? _ _ _ What was the cause of the concern? _ _ _ This workstation is continued on the next page Steering and Suspension Diagnosis 3-5 April, 2007 LESSON THREE WORKSTATION Lesson Three - Scenario Two What was the customer’s concern? _ Record your reading and place the alignment arrows in the correct location on the graphics provided z Circle any readings that are out of specification Steering and Suspension Diagnosis 3-6 April, 2007 LESSON THREE WORKSTATION What repair procedures were performed to correct the concern? _ _ _ What was the cause of the concern? _ _ _ Steering and Suspension Diagnosis 3-7 April, 2007 LESSON THREE WORKSTATION WORKSTATION ELECTRONIC SUSPENSION DIAGNOSIS DIRECTIONS: Complete Workstation at the vehicle workstation SUMMARY: In this activity you are going to diagnose an air suspension concern z Use the following steps to diagnose the concern on the repair order What is the customer concern? _ _ Based on the customer’s concern, what system(s) could be at fault? _ _ Based on the customer’s concern, what component(s) could be at fault? _ _ View the ride height sensor PIDs and log the values below Do the values seem accurate? _ Bounce the vehicle up and down Did the ride height sensor values change? _ z Using output state control, perform the following: Command the compressor ON Does the compressor run? _ Activate the vent solenoid Can you hear air vent? _ Command the air spring solenoids ON Can you hear the air spring solenoids activate? _ z Using output state control attempt to raise and lower the left front, right front, and rear wheels of the vehicle individually Did each wheel raise and lower correctly? Yes / No Right Front: Left Front: Rear: 10 What was the cause of the concern? _ Steering and Suspension Diagnosis 3-8 April, 2007 LESSON THREE WORKSTATION WORKSTATION REAR SUSPENSION CONCERN DIRECTIONS: Complete Workstation at the computer station SUMMARY: In this activity you will read and interpret steering and suspension wiring diagrams Using the 2006 Crown Victoria workshop manual and wiring diagram, answer the questions below What describes the method for adjusting the ride height on a 2006 Crown Victoria with a rear air suspension? A Turning an adjusting screw on the height sensor to read 2.8 volts at trim height B Changing the length of the height sensor connecting link to read 2.8 volts at trim height C Repositioning the height sensor connecting link bracket to read 2.8 volts at trim height D Re-calibrating the air suspension module A customer brings in a 2006 Crown Victoria with rear air suspension and the symptom that the vehicle sits low in the rear You have verified the concern What components would you typically check during a visual inspection on a rear air suspension-equipped vehicle? Electrical Components: _ _ Mechanical Components: _ _ The following tests were performed: z A visual inspection did not reveal any obvious signs of component failure or damage z An RASM self-test did not generate any DTC’s z A pneumatic test was performed and DTC C1726 (Air Suspension Rear Pneumatic Failure) was generated This workstation is continued on the next page Steering and Suspension Diagnosis 3-9 April, 2007 LESSON THREE WORKSTATION Referring to the wiring diagram, what components might be at fault? Circle all that apply A Air suspension module B Air suspension switch C Rear height sensor D Left air spring solenoid E Right air spring solenoid F Air compressor vent solenoid G Air compressor Referring to the wiring diagram, what circuits or grounds might be at fault? A CKT 419 B CKT 421 C CKT 538 D CKT 1114 E CKT 1115 F G 102 G G 210 H G 406 I CKT 417 J CKT 427 K CKT 432 L CKT 635 M CKT 1312 This workstation is continued on the next page Steering and Suspension Diagnosis - 10 April, 2007 LESSON THREE WORKSTATION z The height sensor PID reads 1.49 Volts z The door ajar PID correctly states that all doors are closed z The vehicle can be lowered and raised using Output State Control z You observed that the height sensor PID voltage did not change when raising or lowering the vehicle Referring to the wiring diagram, what components might be at fault? Circle all that apply A Air suspension module B Air suspension switch C Rear height sensor D Left air spring solenoid E Right air spring solenoid F Air compressor vent solenoid G Air compressor Referring to the wiring diagram, what circuits or grounds might be at fault? A CKT 419 B CKT 421 C CKT 538 D CKT 1114 E CKT 1115 F G 102 G G 210 H G 406 I CKT 417 J CKT 427 K CKT 432 L CKT 635 M CKT 1312 This workstation is continued on the next page Steering and Suspension Diagnosis - 11 April, 2007 LESSON THREE WORKSTATION Does a height sensor voltage value of 1.49 volts sent to the module indicate a vehicle sitting above or below correct trim height? A Above B Below z You back-probed pins 1, 2, and at C4043 and your test results are listed below: Pin Number Voltage Measured 0.02 1.50 1.51 Referring to the wiring diagram, what components might be at fault? A Air suspension module B Air suspension switch C Rear height sensor D Left air spring solenoid E Right air spring solenoid F Air compressor vent solenoid G Air compressor Referring to the wiring diagram, what circuits or grounds might be at fault? A CKT 419 B CKT 421 C CKT 538 D CKT 1114 E CKT 1115 F G 102 G G 210 H G 406 I CKT 417 J CKT 427 K CKT 432 L CKT 635 M CKT 1312 10 What is most likely the cause of the customer’s concern? _ Steering and Suspension Diagnosis - 12 April, 2007 STEERING AND SUSPENSION DIAGNOSIS APPENDIX APPENDIX Steering and Suspension Diagnosis Appendix - April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis Appendix - APPENDIX April, 2007 STEERING AND SUSPENSION DIAGNOSIS APPENDIX FRONT SUSPENSION BALLJOINT INSPECTION JOB AID This table indicates the specifications for balljoint deflections as illustrated in the charts on the reverse side Vehicle Model Year BALLJOINT Aviator 2003 - 2005 Front Lower Aviator 2003 - 2005 Front Upper MEASUREMENT DEFLECTION inches (mm) Between Lower Control Arm and Knuckle Between Upper Control Arm and Knuckle 0-0.032 in (0-0.8mm) 0-0.008 in (0-0.2mm) REFERENCE DIAGRAM A C B but a jackstand must be placed under the lower control arm to "load the suspension" C but a jackstand must be placed under the lower control arm to "load the suspension" Crown Victoria Grand Marquis Town Car 1998 - 2002 Front Lower Between Lower Control Arm and Knuckle 0-0.012 in (0-0.3mm) Crown Victoria Grand Marquis Town Car 1998 - 2002 Front Upper Between Upper Control Arm and Knuckle 0-0.008 in (0-0.2mm) 2003 - 2006 Front Lower Between Lower Control Arm and Knuckle 0-0.016 in (0-0.4mm) A 2003 - 2006 Front Upper Between Upper Control Arm and Knuckle 0-0.008 in (0-0.2mm) C 2000 - 2006 Front Lower Between Lower Control Arm and Knuckle 0-0.008 in (0-0.2mm) D 0-0.008 in (0-0.2mm) D Crown Victoria Grand Marquis Town Car Crown Victoria Grand Marquis Town Car Escape Focus Mariner Escort 1998 - 2004 Front Lower Between Lower Control Arm and Knuckle Expedition Explorer Explorer Sport Explorer Sport Trac F150 Mountaineer Navigator Ranger 1998 - 2006 Front Lower Between Lower Control Arm and Knuckle 0-0.032 in (0-0.8mm) A Expedition Explorer Explorer Sport Explorer Sport Trac F150 Mountaineer Navigator Ranger 1998 - 2006 Front Upper Between Upper Control Arm and Knuckle 0-0.008 in (0-0.2mm) C E-Series F-Series Super Duty Excursion 1998 - 2006 Front Lower At Lower Balljoint Between Axle/Twin I Beam and Spindle/Knuckle 0-0.040 in (0-1.0mm) E 1998 - 2006 Front Upper 0-0.024 in (0-0.6mm) F 2005 - 2006 Front Lower 2005 - 2006 Front Lower E-Series F-Series Super Duty Excursion Ford 500 Freestyle Ford GT Ford GT Freestar Monterey Fusion Milan Zephyr Fusion Milan Zephyr Lincoln LS Thunderbird Lincoln LS Thunderbird At Upper Balljoint Between Axle/Twin I Beam and Spindle/Knuckle Between Lower Control Arm and Knuckle Between Lower Control Arm and Knuckle Between Upper Control Arm and Knuckle Between Lower Control Arm and Knuckle 0-0.008 in (0-0.2mm) 0-0.008 in (0-0.2mm) 0-0.008 in (0-0.2mm) 0-0.008 in (0-0.2mm) D A 2005 - 2006 Front Upper 2004 - 2006 Front Lower 2006 Front Lower Between Lower Control Arm and Knuckle 0-0.016 in (0-0.4mm) See Service Manual for Details 2006 Front Upper Between Upper Control Arm and Knuckle 0-0.008 in (0-0.2mm) C Between Lower Control Arm and Knuckle Between Upper Control Arm and Knuckle 0-0.008 in (0-0.2mm) 0-0.008 in (0-0.2mm) 2001 - 2006 Front Lower 2001 - 2006 Front Upper Mustang 1998 - 2004 Front Lower Mustang 2005 - 2006 Front Lower Sable Taurus 1998 - 2006 Front Lower Windstar 1998 - 2003 Front Lower Between Lower Control Arm and Knuckle 0-0.012 in (0-0.3mm) Between Lower Control Arm and Knuckle Between Lower Control Arm and Knuckle Between Lower Control Arm and Knuckle 0-0.012 in (0-0.3mm) 0-0.032 in (0-0.8mm) 0-0.016 in (0-0.4mm) C D A C B but a jackstand must be placed under the lower control arm to "load the suspension" D D D The descriptions and specifications contained in this document were in effect at the time this document was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice, and without incurring any obligation This chart is for OEM Components only and may not apply to Motorcraft specifications Revision Date: July 22, 2005 Steering and Suspension Diagnosis Appendix - April, 2007 STEERING AND SUSPENSION DIAGNOSIS APPENDIX FRONT SUSPENSION BALLJOINT INSPECTION JOB AID DIAGNOSIS See Specification - IMPORTANT See Specification Check for wheel bearing play before checking for ball joint deflection Align the dial indicator as close as possible to the ball joint centerline to minimize error Use Hand Force Only The use of tools or equipment can cause damage and relative movement that may not exist when using hand force only If procedures are not followed correctly, it is possible to get a false measurement resulting in unneccessary replacement Type A: SLA Lower Balljoint (Spring on Shock) Type B: SLA Lower Balljoint (Spring on Arm) See Specification Note: For Types A and B, the hand force applied in an up/down motion at the tire must overcome the weight of the tire/wheel assembly Note: For Types E and F, the hand force applied in an inboard / outboard motion at the tire must be at the and 12 O'Clock Postions and also overcome the weight of the tire/wheel assembly See Specification Type C: SLA Upper Balljoint See Specification Type D: MacPherson Strut Inspection using Lower Control Arm (Coil Spring on Strut) See Specification Type E: Twin Eye Beam / Monobeam Suspension: Lower Balljoint Type F: Twin Eye Beam / Monobeam Suspension: Upper Balljoint Note: The descriptions and specifications contained in this document were in effect at the time this document was approved for printing Ford Motor Company reserves the right to discontinue models at any time, or change specifications or design without notice, and without incurring any obligation Steering and Suspension Diagnosis Appendix - April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis Appendix - APPENDIX April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis Appendix - APPENDIX April, 2007 ... APPENDIX - Steering and Suspension Diagnosis TOC - i April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis TOC - ii TABLE OF CONTENTS April, 2007 STEERING AND SUSPENSION DIAGNOSIS. .. simulated alignment machine Steering and Suspension Diagnosis Intro - April, 2007 STEERING AND SUSPENSION DIAGNOSIS Steering and Suspension Diagnosis Intro - INTRODUCTION April, 2007 LESSON ONE PREREQUISITE... DIAGNOSIS INTRODUCTION INTRODUCTION Steering and Suspension Diagnosis Intro - April, 2007 STEERING AND SUSPENSION DIAGNOSIS INTRODUCTION Steering and Suspension Diagnosis Course Description This