Chassis Technology and Routine Maintenance

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TM2 is a computer-based instructional module that has been designed to teach
the fundamentals of the following topics:

• Suspension Damping and Ride Control
• Suspension Types and Operation
• Wheels, Tires and Wheel Bearings
• Braking Systems
• ABS Braking Systems
• Body
• Steering Systems
• Friction and Bearings
• Servicing

Each topic is divided into a series of on-screen, theory-based interactive
assignments that incorporate continuous assessment through questions. When used in conjunction with a ClassAct networked management system, this provides instant feedback of student performance.

Curriculum material topics include:

Suspension Damping and Ride Control

• Rubber springs
• Fluid/gas springing
• Dampers and types of damper: lever, single tube, twin tube, variable rate
• Bump and rebound stops
• Anti roll bars
• Compliance
• Reasons for self leveling
• Operation of self leveling systems
• Manual ride control systems
• Adaptive damping
• Active suspension
• Active body control
• Air suspension

Suspension Types and Operation

• Glossary of terms
• Main purpose of suspension
• Leaf springs
• Torsion bars
• Coil springs
• Independent suspension
• Suspension arms, links and characteristics
• Forces acting on the suspension
• Live and beam axles
• Semi/trailing and swinging arms
• De Dion axle suspension
• Strut and link nondrive IRS
• McPherson struts
• Torsion beams
• Panhard rods
• Shackles
• Bushes
• Sub-frame assemblies
• Chassis mounting points
• Torque reaction

Wheels, Tires and Wheel Bearings

• Wheel construction, design and fixings
• Tire construction and identification
• Tubeless tires
• Influence of tires on vehicle handling characteristics
• Legal requirements for wheels and tires
• Reasons for, and arrangement of wheel bearings
• Loads imposed on drive shafts, wheels, tires and wheel bearings
• Tire defects related to steering, suspension and usage

Braking Systems

• The science of brakes
• Hydraulic brake principles
• Brake circuits
• Master cylinder types, principles and operations
• Drum brakes
• Wheel cylinders
• Disc brakes
• Brake pads
• Handbrake
• Brake fluid
• Brake servo
• Vacuum pump
• Pressure accumulators and control valves
• Load sensing, inertia and pressure limiting valves
• Hydraulic servo pressure systems
• Legal requirements
• Bleeding ABS and non-ABS systems

ABS Braking Systems

• Types of ABS system
• ABS concepts
• ABS features
• Hydraulic modulator operation
• Control sequence
• EBS brakes

Body

• Function
• Chassis
• Load bearing members
• Monocoque
• Composite
• Vehicle body types
• Door fittings
• Seals
• Windows
• Safety glass
• Trim
• Seats
• VIN plate information
• Legal requirements for safety and testing
• Legal requirements for seat belts
• Legal requirements for window glass, visibility and mirrors
• Legal requirements for seat fixtures
• Legal requirements for steering fixtures
• Legal requirements for body and chassis condition
• Legal requirements for passive and active safety
• Airbags and intelligent airbags
• Total protection

Steering Systems

• Layout and types of steering gear
• Neutral, oversteer, understeer and slip angle
• Steering geometry: castor, camber, toe in/out, swivel axis, offset
• Power assisted steering
• Non-steered wheel and front/rear geometry
• Rear and four wheel steering
• Speed sensitive power steering
• Thrust axis deviation

Friction and Bearings

• Forms of lubrication friction
• Grading/types of lubrication
• Applications of lubrications
• Oil sealing devices and gaskets
• Factors affecting friction between surfaces in contact
• Plain, ball and roller bearings

Servicing

• Contracts
• Starting the job
• Inside, outside and under vehicle tasks (full height and half height)
• Underhood tasks
• Road testing
• Renewal of CB points
• Static and dynamic timing
• Valve clearances
• Drive belt replacement and adjustmentCompetence-based reporting

Each on-screen assignment is designed around a list of performance objectives.
These include academic, technical, and occupational objectives.

The assignments are written in such a way as to enable a student to attain the
performance objectives, with the assessment questions linked to these in order to provide a measure of true competency.

The performance objectives are used by the ClassAct management system to generate a comprehensive portfolio of student competency reports.

The module includes default competence reports that address the requirements of UK Automotive Awarding Bodies.

Instructor Materials

• An Instructor Guide, containing correct answers to all questions.

The items supplied with this instructional module include:

• TM2 On-Screen Multimedia Manual CD-ROM
• Stand Alone eContent Utilities CD-ROM
• TM2 Instructor’s Guide (paper copy)