Professional Documents
Culture Documents
Other wheel
(body
Frame~
inner
structure)
A
not affected
Wheel pushed
up by bump
I
Control
arm Control
bushingarm /
B
Lateral Acceleration made of fiberglass. Although leaf springs were once used
Lateral acceleration is the amount of side force a on front suspension systems, they are now limited to the
vehicle can handle before its tires lose traction and skid rear of some cars. An exploded view of a leaf spring
assembly is given in Figure 67-5.
in a sharp turn. It is measured in units of gravity, or
A monoleaf spring is made of a single, thick leaf,
"g-force" usually on a skidpad (round or circular driving
which is usually made of reinforced fiberglass. Multiple-
course). The higher the "g's" the better. Passenger cars
leaf springs have several thin steel leaves sandwiched
can attain a lateral acceleration of about 1.0 g, while race
together.
cars can produce more than 3.0 g's in turns.
Each end of the leaf spring has an eye (cylinder
Independent suspension systems generally obtain
shaped hole), which holds a bushing. The front spring eye
higher lateral acceleration than nonindependent designs.
normally bolts directly to the frame structure. Two large
They are able to keep all four tires in full contact with the
U-bolts secure the axle or axle housing to the leaf
road surface better than older, heavier, solid-axle designs.
springs. A shackle fastens the rear leaf spring eye to the
t
A Front
disc brake
Front suspension
~'1
7
t>-, ....
Air Spring
Shock An air spring is typically a two-ply rubber cylinder
absorber that is filled with air. End caps are formed on the air
Spring
spring for mounting. Air pressure in the rubber cylinder
bushing gives the unit a spring action, similar to that of a coil
spring. Refer to Figure 67-7.
An air spring is lighter than a coil spring. This gives
jShaCkle it the potential to produce a smoother ride than a coil
spring. Special synthetic rubber compounds must be used
so the air spring can operate properly in cold weather.
Low temperatures tend to stiffen rubber.
Tie plate
-~ ~Frame
Figure 67-7. Air springs are used on some late-model cars. They
are especially adaptable to automatic leveling systems. (Ford)
Acceleration torque
reaction
\,t
Suspension System Construction
Now that you have been introduced to suspension
-'I/ system basics, we will cover the construction of each part
in detail.
Control Arms
Figure 67-8. The torsion bar is twisted with control arm move-
ment. The bar resists twisting action and acts like a conven- A control arm holds the steering knuckle, bearing
tional spring. (Moog) support, or axle housing in position as the wheel moves
up and down. Look at Figure 67-9.
The outer end of a control arm contains a ball joint;
the inner end contains bushings. A rear suspension con-
Spring Terminology
trol arm may have bushings on both ends.
There are several terms relating to springs that you Control arm bushings act as bearings, allowing the
should understand. A few of the most important ones are arm to swing up and down on a shaft bolted to the frame
discussed in the following section. or suspension unit. Bushings may either be pressed or
Spring rate refers to the stiffness, or tension, of a screwed into holes in the control arm.
spring. The rate of a spring is determined by the weight
needed to bend and compress it. Strut Rod
Sprung weight is the weight of the parts that are sup-
ported by the springs and suspension system. Sprung weight A strut rod fastens to the outer end of the lower con-
should be kept high in proportion to unsprung weight. trol arm and to the unibody or frame. It keeps the control
The unsprung weight is the weight of the parts that arm from swinging toward the front or rear of the v~hicle.
are not supported by the springs. The tires, wheels, wheel See Figure 67-8.
@~
-1-_--~~ ...-e--~ __
~
Seal~ ~
Figure 67-9. Study the basic parts of a control arm. Bushings fit into the inner ends of the arm. A ball joint fits into the outer end of
the control arm. The ball joint is connected to the steering knuckle. (Fiat)
Chapter 67 Suspension System Fundamentals 1285
The front of the strut rod contains rubber bushings Lube plug
that soften the action of the rod. They permit a controlled
amount of lower control arm front-to-rear flex while
allowing full suspension travel.
Ball Joints
Balljoints (short for ball-and-socket joints) are con-
nections that allow limited rotation in every direction.
They connect the outer ends of control arms to the
steering knuckle. See Figures 67-9 and 67-10.
Since the ball joint must be filled with grease, a
grease fitting and a grease seal are normally placed on the
joint, Figure 67-11. The end of the stud on the ball joint
is threaded for a large nut. When the nut is tightened, it
draws the tapered stud into the steering knuckle or Upper ball joint Lower ball joint
bearing support, creating a force fit.
Figure 67-11. A ball joint is simply a ball in a socket. The ball
stud is free to move in all directions. This allows the control arm
Shock Absorbers
and steering knuckle to move up and down freely. (Buick)
Shock absorbers limit spring oscillations (compres-
sion-extension movements) to smooth the vehicle's ride.
Without shock absorbers, the vehicle would continue to
bounce up and down long after striking a dip or hump in the
road. This would make the ride uncomfortable and unsafe.
Figure 67-12 shows the basic parts of a shock
absorber. They include a piston rod, rod seal, piston, oil
Seal
assembty
Piston/valving
Piston/valving
assembly
assembly
Diaphragm
"
Pressurized
Drive gas chamber
Hub and axle shaft
wheel
bearing Lower
assembly mount
Rod nut
Coil spring
Dust boot
Strut shock
absorber assembly
Valve
Spindle
Lower
Bushing control arm
Figure 67-14. Study the parts of this strut assembly closely. This is one of the most modern suspension systems and is commonly
used on today's vehicles. (DaimlerChrysler)
~\
Figure 67-15. Exploded and cutaway views of a strut. Note the strut bearing, which allows the front wheel, steering knuckle, and
strut to revolve for steering action. (DaimlerChrysler)
1288 Section 11 Suspension, Steering, and Brakes
Bar-to-axle
through
bolt
Figure 67-17. A track rod is commonly used on the rear axle to prevent side-to-side movement. Note how the rod connects to the
frame and axle. (DaimlerChrysler)
Chapter 67 Suspension System Fundamentals 1289
Coil spring
around strut Spring on lower control arm Coil spring around strut
A (front-wheel drive) B (modified MacPherson strut) c (rear-wheel drive)
Figure 67-19. MacPherson strut suspensions. A-Coil spring around strut, front-wheel drive. B-Modified strut has the coil spring
mounted on control arms. C-Same as A, but without front-wheel drive. (Moog)
Dead Axle
A dead axle is a term used to describe a solid rear
axle on a front-wheel-drive vehicle. Since the front
wheels transfer driving power to the road, the rear axle is
simply a straight, or solid, axle, Figure 67-24.
Semi-Independent Suspension
Semi-independent suspension means that the right
and left wheel are partially independent of each other.
Front-
This type suspension uses a flexible axle, Figure 67-24.
drive
axles When one tire hits a bump, its control arm moves up.
Since the axle can flex or twist, the effect on the other tire
is minimized.
Strut assembly
Lateral
links
Lower
control
arm
Figure 67-21. Compare struts for the front and rear of a vehicle. (Subaru)
--------------------------------------------- ---
1292 Section 11 Suspension, Steering, and Brakes
Coil Stabilizer
spring bar
Figure 67-23. Solid axle housing rear suspension for rear-wheel-drive vehicle. Study the parts. (Ford)
Stabilizer
bar
Bushings
Figure 67-25. Top and side views of a trailing-arm independent rear suspension. Note the location of the bushings, the spring, and
the shock absorber. (Toyota)
Coil
spring
Figure 67-26. This rear drive axle uses a differential that is mounted on the frame. Swing axles extend out to the drive wheels. Note
the trailing arms and the other components. (Mercedes Benz)
Compressor assembly-motor-powered air pump Air shocks-air-filled shock absorbers that act on
that produces pressure for the system. the suspension system to alter ride height.
Pressure lines-air hoses that connect the com- Sensor link-linkage rods that connect the height
pressor to the air shock absorbers. sensor to the suspension.
1294 Section 11 Suspension, Steering, and Brakes
Upper control
arm
Sway bar
control
Upper
arm \ Lower
control
arm
Figure 67-27. This double wishbone suspension system is a long-short arm design. Note how the lower trailing arms have been
lightened by forming holes in them. This improves ride smoothness. (Honda)
Rear air
Open door springs
sensor and height
switch sensor
Figure 67-29. Suspension leveling system using air springs. Study the parts. (Ford)
When the weight is removed from the trunk, the car Electronic control module-small computer that
body will rise. The height sensor switch will then be uses sensor inputs to control the shock actuators.
moved in the other direction by the link. This closes Shock actuators-solenoid-operated valves that
another set of contacts in the switch, energizing the pres- control fluid flow inside the shock absorbers.
sure release solenoid valve. Air pressure is then expelled
If a car is being driven on curving country roads, the
from the rear shocks until the body drops down the cor-
driver might switch to a stiff setting with the mode
rect ride height. switch. The electronic control module would then ener-
gize the shock actuators to close or restrict the shock
Electronic Suspension System absorber valves to increase dampening action. This
An electronic suspension system uses various sen- would stiffen the ride and make the car comer better.
sors, a computer, and shock absorber actuators to control If driving on a rough highway, the mode switch
ride stiffness. It is designed to increase comfort and might be moved to a soft setting. The electronic control
safety by matching suspension system action to driving module would then energize the shock actuators to open
conditions, Figure 67-30. the valves more. This would soften the ride by allowing
Although exact designs vary, the major components easier shock movement.
of a typical electronic shock absorber system include: Under hard braking, the brake sensor would send a
Steering sensor-detects steering wheel rota- signal to the electronic control module. The control
tional direction and speed and feeds data about module could then stiffen the shocks to prevent the front
vehicle direction to the computer. of the car from diving.
With rapid turning or cornering, the steering sensor
Brake sensor-usually, the brake light switch is
could also signal the electronic control module. The
used to report when brakes are applied.
module could then stiffen the shocks to prevent excess
Acceleration sensor-usually, the throttle posi- body roll, or lean, in turns.
tion sensor is used to detect when car is acceler-
Figure 67-31 shows one type of shock actuator. Note
ating rapidly. how it uses a solenoid and a small DC motor to act upon
Mode switch-dash-mounted switch that allows the shock absorber control rod. The control rod can be
the driver to choose the desired shock action or moved up or down to control fluid flow resistance and
ride stiffness. shock stiffness or dampening.
1296 Section 11 Suspension, Steering, and Brakes
Shock actuators
Stop light switch
Throttle position
sensor
Neutral start
switch
A Test connector
Shock actuator
I - - - - - Sensors - - - - - ,
I I Suspension
I I control Shock actuator
I Speed sensor
I computer
I
I Shock actuator
Steering sensor
I
I
I
I Stop lamp switch
I
I
I Neutral start switch TEMS indicator
I
I (AfT vehicle)
I
I
ECU
: Throttle position sensor I
L I
B
Figure 67-30. A-This electronic suspension system automatically adjusts shock stiffness to match driving and road conditions. For
instance, it will produce a soft, smooth ride when traveling down a straight highway. However, it will stiffen shock dampening when
cornering on a country road. B- This block diagram shows how various sensors feed electrical data to the suspension control com-
puter. The computer can then energize the shock actuators to modify ride stiffness and shock action. (Toyota)
Some cars use air shocks or air bags instead of determined by the amount of time needed for the waves
hydraulic shock absorbers. The operation of these sys- to strike the road surface and bounce back. The computer
tems is similar. uses the output signals from the sonar sensor to deter-
One type of electronic shock absorber system uses a mine proper ride stiffness. If, for example, there is a dip
sonar sensor to detect changes in road conditions. The in the road, the sound waves will take longer to return to
sensor, which is mounted at the front of the vehicle, pro- the sensor. This will cause the sensor to modify its output
duces sound waves. These waves bounce off the road and signal. The computer analyzes the sensor's output signals
back into the sensor. The sensor's output signal is and adjusts shock action as necessary.
Chapter 67 Suspension System Fundamentals 1297
Solenoid
Pinion gear
Sector gear
Shock absorber
piston rod
Power
Figure 67-31. This shock actuator uses small electric motor transmission
and a solenoid to move the shock piston rod in and out. Piston
rod movement alters shock dampening action.
Pressure
Suspension system springs must jounce (com-
control press) and rebound (extend) with bumps and
valves holes in the road surface.
A control arm holds the steering knuckle, bearing
support, or axle housing in position as the wheel
moves up and down.
Hydraulic
ram
A strut rod fastens to the outer end of the lower
reservoir control arm and to the frame. It keeps the control
arm from swinging toward the rear or front of the
Causes C vehicle.
~ pressure
rop
ressuri rise
auses Ball joints (short for ball-and-socket joints) are
connections that allow limited rotation in every
direction.
Shock absorbers limit spring oscillations (com-
Figure 67-33. This simplified illustration shows the major com- pression-extension movements) to smooth the
ponents of an active suspension system. A pressure sensor on vehicle's ride.
the hydraulic ram reacts to the up-and-down movement of ram A strut assembly consists of a shock absorber, a
and the resulting pressure changes. If pressure in the ram rises
coil spring (most types), and an upper damper
when the wheel hits a bump in the road, the sensor signals the
unit.
computer. The computer can quickly react to release ram pres-
sure so the suspension moves upward with the wheel. As the A sway bar, also called stabilizer bar, is used to
wheel travels down on the other side of the bump, the sensors keep the body from leaning excessively in sharp
make the computer increase ram pressure so that the suspen- turns.
sion travels back down to the original road surface.
Jounce bumpers are blocks of hard rubber that
keep the suspension system parts from hitting the
frame or body when the vehicle hits large bumps
Highway History or holes.
The Ford Model-T was the first mass-produced
A long-short arm suspension uses control arms of
passenger car. Affectionately called the "Tin Lizzie,"
this vehicle was first introduced in 1908. It was different lengths to keep the tires from tilting with
deemed "the car for the multitude" and was an instant suspension action.
success. Henry Ford developed this car and suc- A MacPherson strut suspension uses only one
ceeded in building one of the largest automobile- control arm and a strut assembly (spring, damper,
manufacturing companies in the world. and shock absorber unit) to support each wheel
assembly.
A dead axle is a term used to describe a solid rear
Summary axle on a front-wheel-drive vehicle.
The suspension system allows the tires and A suspension leveling system is used to maintain
wheels to move up and down over bumps and a constant vehicle attitude (height ratio between
holes in the road surface. front and rear of body) as the amount or distribu-
tion of weight in the vehicle changes.
Chassis stiffness is a primary factor affecting how
quiet and smooth a vehicle drives-the stiffer the To maintain correct ride height, an electronic
chassis, the better. height control system uses height sensors and an
ECM to control the operation of a small electric
Independent suspension allows one wheel to
aIr compressor.
move up and down with little effect on the other
wheels.
Chapter 67 Suspension System Fundamentals 1299
An electronic shock absorber system uses various Pressure lines Brake sensor
vehicle sensors, an electronic control module, and Air shocks Acceleration sensor
shock absorber actuators to control ride stiffness. Sensor link Mode switch
Solenoid valve Electronic control
An active suspension system uses computer-con-
Suspension control module
trolled hydraulic rams instead of conventional
module Shock actuators
suspension system springs and shock absorbers.
Electronic suspension Active suspension
system system
Important Terms Steering sensor
11. Technician A says coil springs are used on 15. Technician A says the term "dead axle" is used
either the front or the rear of an automobile. to describe a solid rear axle on a front-wheel-
Technician B says coil springs are only used drive vehicle. Technician B says the term
on the front of an automobile. Who is right? "dead axle" refers to a solid rear axle on an
(A) A only. independent suspension system. Who is right?
(B) B only. (A) A only.
(C) Both A and B. (B) B only.
(D) Neither A nor B. (C) Both A and B.
12. Technician A says a torsion bar fastens to the (D) Neither A nor B.
vehicle's frame. Technician B says a torsion
bar fastens to the suspension system control
arm. Who is right? Activities-Chapter 67
(A) A only. 1. Prepare an overhead transparency (or trans-
(B) B only. parencies) showing the basic parts of a suspen-
(C) Both A and B. sion system. (You can trace and/or enlarge
(D) Neither A nor B.
Figure 67-1 onto the transparency material and
13. Technician A says most automotive shock label the parts.) Use the transparency to explain
absorbers are filled with oil. Technician B says to the class the function of each part of the
most automotive shock absorbers are fIlled system.
with air. Who is right? 2. Examine vehicles in the shop and identify the
(A) A only. type of suspension in each.
(B) B only.
3. Join a discussion on the merits of different sus-
(C) Both A and B.
(D) Neither A nor B. pension systems.