ASE T5

1. The truck with the air suspension system shown above leans to the right. Technician A says that valveX could be the cause. Technician B says that valve Y could be the cause. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

1. The correct answer is C, both technicians are right. Height control valves can fail in either direction-that is, by controlling the height at too great a level or at too low a level. If the truck leans, the cause can be either too great a height on one side or too low a height on the other. Until the technician knows that one side is too high or the other too low, he must assume that either valve might be malfunctioning.

10. The steering gear sector shaft preload is to be set. Technician A says the steering wheel must be in the center position. Technician B says the drag link should be disconnected from the pitman arm. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

10. The correct answer is C, both technicians are right. The steering wheel must be in the center position because clearances in the box change (they are tightest at center) and setting preload at another position would cause binding at the center. The drag link must be disconnected because preload is measured by turning the steering box. It produces a very small amount of friction that must be measured with an inch pound torque wrench and is much smaller than the friction inherent in the rest of the steering system.

11. Which of these could cause the front tires of a truck to show a feather-edged wear pattern? A. a wrong toe-in setting B. a wrong camber setting C. a wrong caster setting D. wrong tire pressure

11. The correct answer is A. Toe-in that is incorrect causes the entire tread to contact the road at an angle; this is what produces feather-edge wear. Incorrect camber causes wear on one side of the tire because it contacts the road unevenly, from side-to-side, when camber is incorrect. C is not the answer because caster that is incorrectly set can produce poor steerability, but usually does not critically affect tire wear. Wrong tire pressures produce wear that is excessive at center or on both sides.

12. The driver of a new truck says that he feels a light tire thump. Technician A says the cause could be an out-of-balance tire. Technician B says the cause could be an over-inflated tire. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

12. The correct answer is A. A tire that is out of balance produces uneven forces in the steering system, The tire tends to bounce up-and-down as the heavier portion alternately goes over the top and hits the pavement. Tires that are overinflated still produce constant forces on the steering system. Overinflation tends to create uneven wear and may cause imprecise steering because the full width of the tread does not contact the road surface.

13. A vehicle has exhibited power steering fluid leakage. Disassembly of components has revealed deteriorated seals in both the pump and steering gear. Technician A says to find out if the vehicle has been run severely overloaded. Technician B says to check for use of an incorrect replacement hose. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

13. The correct answer is C, both technicians are right. The most likely cause of the problem is overheating of the fluid because all the seals in the system deteriorated. Running a vehicle severely overloaded or installing a hose with too small a diameter could overheat the power steering fluid and create widespread failure of the system's seals.

14. During inspection of a tire, a technician finds a slight bulge in one area of the tread. The next step taken should be: A. Remove the tire from the rim and seal the inner liner (the bulge probably results from an air leak). B. Replace the tire as its use is in violation of CVSA regulations and would put the truck out of service if it were subjected to a roadside inspection. C. Have the tire retreaded. D. Measure the size of the bulge to see if it is no greater than 3/8 inch and look for a small, blue triangle stamped into the tire nearby.

14. The correct answer is D. A bulge not exceeding 3/8-in. and marked by a blue triangle indicates that the tire is bulging not because of a structural defect but because of a section repair. The blue triangle merely indicates a repair has been made. A tire that has a bulge from a repair of a dimension within the 3/8-in. limit will pass a roadside inspection without any problem and will operate safely.

15. Technician A says that when diagnosing a power steering leak, the wheels should be in a straight-ahead position. Technician B says that when diagnosing a power steering leak, the steering wheel should be rotated from stop-to-stop to put pressure on the system. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

15. The correct answer is B. When diagnosing a power steering leak, the area should be clean and the system should be full of power steering fluid. The engine should be started and the steering wheel rotated from stop-to-stop, making sure the wheel is not held against either stop for more than two seconds.

16. A truck's leaf springs have broken at a low mileage. A careful inspection reveals no problems related to the spring system, such as frozen shackle bushings or worn hangers, bushings or spring pins. The truck has not been run overloaded. Technician A says the problem may have occurred because the -bolt nuts were not retorqued at specified intervals after the springs were replaced. Technician B says the whole problem could be re-use of old U-bolts or installation of an inferior type of U-bolt. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

16. The correct answer is C, both technicians are right. Leaf spring stacks are extremely sensitive to proper mounting. They naturally tend to settle especially shortly after being installed. U-bolts must be of extremely high quality to retain torque adequately. Thus, the best procedure would be to replace the U-bolts with an approved part, torque the nuts to specification and be sure to retorque them at specified intervals.

17. A truck exhibits a strange combination of symptoms. The drive axles exhibit chronic seal wear problems. At the same time, there is some evidence of irreqular drive axle tire wear. There is no evidence of driveshaft imbalance or worn driveshaft parts. The MOST likely cause of the problem is: A. driver abuse of the truck by frequently popping the clutch in very low gears on a steep upgrade B. severe imbalance of the drive axle tires and wheels C. worn shock absorbers on the tandem drive axle suspension system D. worn bushings in the torque rods locating the drive axles

17. The correct answer is D. Worn bushings in the torque rods are causing the drive axles to sometimes run with their mounting angles incorrect. This, in turn, is causing the symptoms because the driveshafts sometimes operate at excessive angles. This excessive angularity causes vibration, which eventually reaches the seals and destroys them. Also, incorrect operating position causes the tires in the tandem setup to track improperly (work against each other), causing the symptoms noted. Popping the clutch frequently would be more likely to produce twisted or worn driveshafts and rapid tire wear as opposed to irregular wear. Severe imbalance, although it would wear the tires irregularly, would not tend to impact the seals. Worn shocks might cause tire wear if they were almost completely ineffective, but they would not likely cause a seal problem.

18. A truck has exhibited problems with spring leaf failure that can be explained by inadequate clamping force. During an inspection, a technician is having trouble deciding whether or not a particular spring stack is adequately clamped. He knows the fasteners are properly torqued, but suspects bad fasteners have been used and wants a quick way to determine whether or not attaching parts should be replaced to protect the springs from further problems. Technician A says that if the stack feels and looks tight and parts retain the required torque after a few miles of operation, the fasteners are working. Technician B says to rap the U-bolt with a brass hammer. If the bolt yields a ringing sound, torque is probably OK. If it vields a dull thud, it should be replaced. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

18. The correct answer is B. Pull-around torque or the torque required to turn a fastener is not always an indicator of clamping force. On the other hand, a U-bolt that exhibits a ringing sound is probably under sufficient tension to hold the stack secure, while one that exhibits a dull thud is not tight enough.

19. A tractor with a single height control valve exhibits a ride height that is consistently too high. A brief inspection has revealed that the height control valve is in reasonable mechanical condition and properly adjusted. Technician A says to check the air brake system operating pressure and make sure it is not too high. Technician B says to check the physical condition of all the shock absorbers as well as all the travel stops that may be incorporated in the suspension. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

19. The correct answer is B. The shocks and travel stops are probably not working properly. Even with a high brake air system pressure, the control valve will shut off tight, sealing even with excessive pressure at the proper ride height. On the other hand, if suspension travel is excessive in the downward direction, this can allow the truck to ride at too low a height for a brief period over hard bumps. This tricks the control valve into feeding air to the system when it is not actually needed.

2. The driver of a truck says that he hears a clattering noise from the front axle when driving on a rough road. Technician A says the cause could be worn shock absorber mounting bushings. Technician B says the cause could be worn shackle bushings. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

2. The correct answer is C, both technicians are right. Either a worn shackle bushing or worn shock bushing can cause noise due to looseness when the truck hits a good bump. If there is clearance between the rubber bushing and mounting bolt, or if the rubber bushing has worn very thin, elongated or even broken and fallen out, the result will be a clattering noise as the motion of the suspension repeatedly takes up the clearance first in one direction and then in the other.

20. A truck fleet has had repeated tire blowouts. Technician A says they should review their tire changing procedures to make sure the proper tire changing tools and sealing solvents are being used. Technician B says they should review their repair procedures and make sure they are sealing a tire's inner liner when a puncture occurs. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

20. The correct answer is C, both technicians are right. Either improper tire changing procedures or such incorrect repair procedures as failure to seal the inner liner can result in insidious damage and a blowout down the road.

21. A technician has been asked by a customer if he can get more even tire wear, and thereby improve tire life, by rotating the eight tires on the tandem drive axles of his tractor. Technician A says all the tires endure practically identical stresses and wear patterns. Technician B says irregular wear patterns will be canceled out. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

21. The correct answer is B. Tread wear is uneven on tandem drive axles for two reasons: First, the distribution of power is not perfectly equal between all the wheel positions and rotation will equal out the variations. Second, when a tandem axle tractor takes a corner, the forward axle's tires scrub a bit more than those on the rear axle; rotation equalizes this wear, too.

22. When checking the front-end alignment on a truck, it is necessary to add and the included angle: A. kingpin inclination and toe-in B. caster and camber C. kingpin inclination and camber D. toe-in and caster

22. The correct answer is C. This is because this sum gives the relationship between the centerline of the wheel and the centerline of the kingpin (or knuckle support pivots with lighter duty type front axles). This angle is built into the knuckle forging and remains constant unless the spindle is damaged during use. Toe-in and caster do not have any effect on this angle.

23. Which of these is the LEAST likely cause of too much front tire wear? A. underinflated tires B. out-of-balance tires C. a wrong toe-in setting D. a wrong caster setting

23. The correct answer is D. Caster does not affect the way the tread contacts the road or cause the tire to scrub down the road at an angle. Underinflation forces the edges of the tire to take most of the load, concentrating wear, as well as producing excessive flexing (squirming) of the tread and consequent wear. Tires that are out of balance focus wear where the heavier portion of the tire slaps against the road. Toe-in makes the tread scrub across the road, causing featheredge wear.

24. All of these must be checked before aligning the front wheels on a truck EXCEPT: A. tire pressure B. trim height C. wheel bearing adjustment D. tire balance

24. The correct answer is D. Tire balance is the only one of the four factors that does not affect alignment readings. An unbalanced tire will still hold the vehicle at the right height, and sit at the same angle to the vehicle as an unbalanced tire. Tire pressure affects ride height and, therefore, can affect the angle between the frame (and front axle) and the ground. This, in turn, affects the angles of the kingpins, which is what determines caster. Trim height affects frame angle and will affect alignment just as incorrect tire pressure will. Wheel bearing adjustment that is incorrect will change the angle between the wheel and frame and, therefore affect alignment reading.

25. The driver of a truck with power steering says that it takes too much effort to steer. Any of these could be the cause EXCEPT. A. too low a power steering fluid level B. front-end out-of-alignment C. too much steering gear backlash D. a sticking relief valve

25. The correct answer is C. Excessive backlash in the steering gear reduces operating friction in the steering box and will therefore only make the vehicle easier to steer. The symptom associated with excessive backlash would be vague steering. Low fluid level will tend to aerate the fluid and deprive the power system of hydraulic force, making for hard steering. Front end alignment factors that are incorrect will increase steering effort considerably (often by increasing caster action). A sticking relief valve will usually cause bypass of fluid pressure, depriving the power steering gear of necessary hydraulic pressure, making the system behave almost like manual steering.

26. A truck with air suspension repeatedly exhibits shock breakage. All of these are items that should be checked EXCEPT: A. Check the part numbers of the shocks and make sure they are correct for the vehicle. B. Check the function of the ride height control valve. C. Check the torque of the shock mounting bolts. D. Check to make sure the vehicle's tire pressures are not excessively high.

26. The correct answer is D. Though high tire pressure might make the vehicle ride harshly, they are not known to create sufficient stress on the shocks to break them. Misapplied shocks might break due to inadequate travel or insufficient capacity to keep the suspension system operating in a stable manner. The ride height control valve should be checked because an incorrect ride height could cause the shock to constantly hit the upper or lower limit of its travel. Mounting bolt torque should be checked because excessive torque could pinch the shock bushings, prevent them from allowing the shock to rotate freely as necessary, and so put excessive stress on the body of the shock.

27. A truck steers to the right practically all the time. All of the following are probable causes that should be checked out EXCEPT: A. incorrect caster setting B. incorrect camber setting C. loose suspension components D. malfunctioning brake slack adjuster

27. The correct answer is C. Loose suspension components might cause the truck to steer off course, but the effect would come and go as suspension play developed and went away as the truck went over bumps. Caster and camber are alignment settings that, if incorrect, would constantly hold the wheel at an incorrect angle for straight steering. A malfunctioning auto slack adjuster, if it consistently adjusted up too tight, would cause the brake on one side to constantly increase the rolling resistance for that one wheel. This, in turn, would cause the vehicle to steer to one side unless the operator compensated with the wheel.

28. The vehicle's suspension system must do all of the following EXCEPT: A. support the load B. articulate the load (that is, maintain alignment during up-and-down motion) C. remove excess energy that otherwise becomes stored up in the springs and prevents smooth ride D. provide a rigid foundation for frame or trailer support

28. The correct answer is D. The suspension system is, by nature, not rigid, as a rigid system would transfer all the energy generated as the wheels run over bumps to the frame and the load. Even systems designed to support extreme loads at least incorporate rubber cushioning. The system must obviously support the load, keep the vehicle's axles and frame in appropriate alignment for safe steering and level support, and remove excess energy (with shock absorbers)

29. Which of the following is NOT a characteristic of air suspension: A. The ride is smoother when the truck runs empty. B. is more often used on drive and trailer axles than on the front axle C. does not provide much roll stiffness (allows the vehicle to lean more in turns than springs) D. has springs that usually last a long time

29. The correct answer is C. Air suspension gives excellent roll stiffness because the supporting springs are not also used to control articulation- that is left to separate blades and hinge-type joints. The height control valve reduces air pressure, softening the springs, when the vehicle is unloaded. Front axles carry a more constant weight and therefore benefit less from the ability of air suspension to adjust for weight. Air springs are so flexible that they tend not to be subjected to fatigue. Also, the air springs are not stressed if suspension parts begin to lose their freedom of operation due to imperfect maintenance.

3. The driver of a truck that has just had its front springs and hangers replaced says that it is hard to keep the steering wheel in a straight-ahead position. Technician A says the cause could be that the caster shims were installed backwards. Technician B says the cause could be that the wrong spring hangers were installed. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

3. The correct answer is A. Correct caster is critically important in keeping tires at the right angle and enabling the steering system to maintain directional stability. Since the caster shims would have to be removed for this work to be done, it's quite logical to assume they might have been installed backwards, which would create the critically incorrect caster setting that would make the truck wander severely.

30. All of the following basic principles apply to sound leaf spring suspension repair procedures EXCEPT: A. If a truck has run for a long time with a broken spring leaf, replace the entire set. B. Never retorque the nuts that fasten U-bolts because this will stretch the bolts excessively (they were stretched to their limit during initial torque, if it was properly done). C. If a single leaf in a set of long front springs breaks, replace the entire set, even if you think you've caught the problem promptly. D. Never re-use U-bolts because they stretch during normal initial torque.

30. The correct answer is B. Two retorquings are typically required. Retorquing simply restores the bolt to its optimum stretch as the spring stack settles. All the other principles are known means of helping the technician give the vehicle owner a lasting repair. All of them relate to catching excessive stress, which is created when there is a failure because the spring suspension behaves as a system, not a collection of individual parts.

31. A truck's power steering pump has an internal failure. The power steering fluid has been checked and it is no signs of discoloring or contamination have been found. Technician A says after the pump is replaced, any type of power steering fluid is acceptable to use in the system. Technician B says after replacing the pump, the system should be flushed. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

31. The correct answer is D, neither technician is right. Always use the type of power steering fluid specified by the vehicle manufacturer since fluid requirements may vary from one vehicle to another. Component failure can result if fluids are mixed once a specific type is established. Only if it is necessary to change the type of fluid, or the fluid becomes contaminated or discolored, is the entire system to be flushed.

32. A technician is replacing a truck's kingpins. He has measured the kingpin bores and found them to be over the manufacturer's specifications. What should he do next? A. discard the axle B. install shims C. check to see if oversized kingpins are available D. none of the above

32. The correct answer is C. Once the kingpin bores are found to be oversized, the bore can be reamed to allow installation of an oversized kingpin- if manufacturer's specifications say that this is an option. Only if oversized kingpins are not an option should the axle be replaced.

33. Technician A says that camber on a truck should be slightly positive. Technician B says that negative camber compensates for the normal deflection of the axle and front suspension joints. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

33. The correct answer is A. Trucks typically run a slight, positive camber with the vehicle off the front wheels. It is positive camber that compensates for the normal deflection of the axle and front suspension joints as the front suspension is loaded, not negative camber.

34. A technician plans to replace tires on a truck with normal tire tread wear. He has inspected the suspension and steering systems and no defects have been found. After he has replaced the tires, what should he do with the old tire casings? A. have the casings retreaded B. discard the casings C. use them on an off-road truck D. use them on a trailer

34. The correct answer is A. Basic tire designs share a common casing. When tread is worn, the casing can be retreaded with a different type tread and used in a different wheel position. It can also be used in a different geographic section of the country, where traction requirements are different or as required by the customer. The technician can send the casings to a certified retreading facility to have new treads installed. While tread wears relatively rapidly and lasts only a year or two (100,000 to, at maximum, 200,000 miles), the casing itself- the tire's basic structure- is an extremely expensive, durable and reusable item.

35. A truck's frame is being inspected, and a crack has been found in the side rail that is moving toward the bottom flange around the radius of the rail. According to CVSA Out of Service Criteria, the crack should be no longer than: A. 2-in. B. 3½ -in. C. 3¼ -in. D. 1½-in.

35. The correct answer is D. When there is a crack of 1½-in. or longer in the frame side rail that is directed toward the bottom of flange around the radius of the rail, the vehicle can be placed out of service at a road-side inspection.

36. Technician A says that when a kingpin is found to be loose, it can be adjusted. Technician B says that lubricating the kingpin will only temporarily solve the problem. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

36. The correct answer is B. Lubricating the kingpins will help eliminate some play, but only temporarily. Excessive play in the kingpins can only be remedied by replacing the kingpins and bushings.

37. Technician A says that hub piloted wheels and their hardware CANNOT be used on an axle with stud piloted wheels. Technician B says that on dual wheels, hub piloted wheels and stud piloted wheels CAN be mixed. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

37. The correct answer is A. Hub piloted disc wheels are centered on the wheel hub by means of indents built into the hub assembly. The center hole of the disc rests on these indents and centers the wheel. Two-piece flange nuts make contact with the face of the disc at the stud hole. There is no ball seat at the stud hole, since the flange nuts tighten flat against the disc wheel. Stud piloted disc wheels use the secured nuts to center the wheel onto the hub assembly. These wheels have a ball seat at the stud hole, and wheel centering occurs when the securing nuts are tightened in the proper fashion. Although they may have the same bolt hole patterns, don't mix hub piloted disc wheels and their hardware with stud piloted disc wheels. Damage to wheels or studs, and possible wheel loss can result.

38. Tire tread depth in two adjacent tread grooves should not be less than: A. 1/32-in. B. 3/22-in. C. 2/32-in. D. 3/64-in.

38. The correct answer is C. Measurement of the tire tread depth in two adjacent tread grooves should not be less than 2/32-in.

39. All of the following will cause excessive steering looseness EXCEPT: A. sector shaft adjustment loose B. worn linkage C. excessive gear worm end-play D. loose power steering belt

39. The correct answer is D. A steering gear shaft adjusted too loose, worn steering linkage, or excessive steering gear worm end-play will cause the steering to seem loose. A loose power steering belt will impede power assist and cause the steering to be hard.

4. The drive axles on a truck with a walking beam suspension are out of alignment in a manner that is causing vehicle tire wear and steering instability. Technician A says the cause could be that the torque rods are too long or too short. Technician B says the cause could be worn walking beam bushings. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

4. The correct answer is B. The beam bushings maintain horizontal alignment of the axles, especially on turns. When bushings are worn, the beam on either side can move forward or backward, turning the axles in relation to the frame and causing the type of misalignment that causes tire wear and steering problems.

40. Technician A says radial runout on cast spoke wheels can be adjusted by loosening and retorquing the rim clamps. Technician B says to adjust runout on disc wheels, the tire must be separated from the rim and rotated 180 degrees. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

40. The correct answer is C, both technicians are right. Radial runout can be checked on cast spoke wheels by loosening and retorquing the rim clamp nuts according to manufacturer's procedures. On disc wheels, the tire must be deflated and rotated 180 degrees to achieve proper runout.

41. It is recommended to retorque wheel studs and nuts after: A. 100-200 miles B. 50-100 miles C. 300-350 miles D. never

41. The correct answer is B. Retorquing a short time after installation (50 to 100 miles) to ensure full seating is important. Retorquing at an appropriate interval even when wheels are not removed is also an important adjunct to operating safety. Consult the manufacturer for torque specifictions and procedures and retorquing mileage intervals.

42. Steering wheel free-play for a 16-in. steering wheel should be: A. 6⅜ inches B. 6¾ inches C. 5⅜ inches D. 5½ inches

42. The correct answer is B. When troubleshooting a power steering gear, check the steering wheel play against CVSA allowable maximums. The movement measured in inches for a 16-in. steering wheel is 6¾ inches.

43. Which of the following is the LEAST likely to cause chronic spring breakage: A. seized shackle bushings B. worn spring hangers C. loose kingpins D. improper U-bolt torque

43. The correct answer is C. Although kingpins are a critical part of the suspension system, loose kingpins would not cause chronic spring breakage.

44. Technician A says when a single wheel stud is cracked or damaged, the vehicle can run without replacing the stud. Technician B says if a single wheel stud is cracked or damaged, all studs on that wheel should be replaced. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

44. The correct answer is B. The technician should check the stud nuts for cracks, abnormal wear and stripped threads. Should a single stud be broken or damaged, the entire group of studs should be replaced to avoid future failure that may not be apparent during an examination of the studs or nuts.

45. All of the following characteristics describe a remote mounted power steering reservoir EXCEPT: A. mounted inside the engine compartment B. mounted higher than the power steering pump C. vented to the atmosphere D. sealed with an O-ring or gasket

45. The correct answer is D. The remote reservoir tank is mounted inside the engine compartment, and is located in a position that allows downward flow of fluid to the power steering pump. This creates a constant flow of fluid and decreases the chance of pump cavitation. Most reservoirs are vented to the atmosphere through an opening that lets air leave or enter the space above the oil as the oil level rises or falls. The pump mounted power steering reservoir is sealed to the power steering pump using an O-ring or gasket.

46. What is the meaning of the acronym DIP? A. diagnose, install, position B. drive, inspect, pressure C. deflate, inspect, protect D. none of the above

46. The correct answer is C. For the safety of the repairman, the acronym DIP should be remembered when working with tires and wheels. It stands for DEFLATE- the tire before working on it. INSPECT-the rim, rings, lug holes and tires for damage, including distortion and proper sealing. PROTECT- yourself by placing the tire and wheel assembly in an inflation cage before inflating.

47. Technician A says the air-assist safety valve should cut off steering assist when the dash mounted reservoir air pressure gauge drops to 60-65 psi. Technician B says that turning the adjustment screw counterclockwise will lower the valve's cutoff point. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

47. The correct answer is C, both technicians are right. The air-assist safety valve should cut off steering assist when the dash mounted reservoir air pressure gauge drops to 60-65 psi. Turning the screw clockwise will raise the cutoff point; turning it counterclockwise will lower the cutoff point.

48. While driving down a smooth straight road, a truck driver says that it is hard to keep the truck going in a straight line. What is the LEAST likely cause? A. lack of lubrication in the steering gear B. steering gear loose at the frame mounting C. pitman arm loose at the steering gear D. excessive air pressure in the tires

48. The correct answer is D. Excessive tire pressure usually causes a hard ride, excessive wheel bounce, and excessive center tread wear. When the vehicle darts out of a steered line or oversteers, the problem can be attributed to a poorly lubricated steering gear, loose steering gear mountings, or a loose pitman arm at the steering gear.

49. Technician A says a power steering cooler helps to keep the fluid temperatures low in normal operating situations. Technician B says a power steering cooler will keep the system from overheating in the event of a failure. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

49. The correct answer is A. A power steering cooler keeps fluid temperatures low, promoting longer component life and reducing the potential for leaks in normal operating conditions. However, the cooler will not keep the lubricant temperatures low if there is another failure in the system that is causing fluid burn.

5. The driver of a truck says that it is too hard to steer and that the steering wheel return is too fast. Which of these is the most likely cause? A. too much negative caster B. too much positive caster C. too much negative camber D. too much positive camber

5. The correct answer is B. Caster action is the most critical suspension alignment specification in terms of affecting steering wheel return to the center. Caster actually lifts the truck as the wheel is turned in either direction; when the driver allows the wheel to return to center, the weight of the truck actually forces the steering system to that position. When the caster setting is too high, the weight of the truck exerts too much force in centering the steering and creates the symptoms noted.

50. What is the maximum deflection of the front axle when a technician is bending it to achieve a correct camber reading? A. ¼ inch B. ½ inch C. ⅜ inch D. ¾ inch

50. The correct answer is B. Although camber is not adjustable on most trucks, minor bending of a solid beam axle can correct some camber alignment problems if the bends are made by qualified personnel. However, these adjustments are not recommended by most vehicle manufacturers. The bends may deflect the axle up to approximately 1/2-in. and should be done cold with special equipment. Do not apply heat to the axle in order to bend it as that portion could be weakened.

51. Leaf springs are divided into which of the following categories? A. tri-point and dual-point B. single-point and dual-point C. dual-point and variable rate D. constant-rate and tri-point

51. The correct answer is B. Leaf spring suspensions are divided into two basic categories: Single- and dual-point. Single-point types use a beam that has bushings on both ends. The spring uses front and rear hangers. Torque rods locate the axles laterally. Dual-point types have four springs instead of two. An equalizer allows a degree of articulation between the axles in some designs.

52. A truck with dual wheels comes into the shop with one inner tire that is flat. Technician A says the tire must be repaired or replaced before leaving. Technician B says the scrubbing of the tire along the road could cause a fire. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

52. The correct answer is C, both technicians are right. A truck with a flat on one of its dual wheels must have the tire repaired immediately. The 'cardinal sin' is running dual wheels with one tire flat, which causes critical overheating of the tire carrying the entire load. This may even cause the flat tire to catch on fire due to scrubbing the tread along the road.

53. Technician A says that toe-in counteracts positive camber. Technician B says as parts wear, toe-in increases. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

53. The correct answer is A. Toe-in performs the function of preloading steering linkage joints and counteracts the wheel's tendency to pull outward at the front due to positive camber. As the required camber increases, generally so does the toe-in. Note that toe-in decreases as parts wear.

54. Technician A says that fifth wheel stops keep the trailer pin from sliding inside the fifth wheel. Technician B says some trucks have an air-operated fifth wheel locking control. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

54. The correct answer is B. Fifth wheel stops keep the fifth wheel from sliding from the mounting bracket assembly. These stops are welded to the fifth wheel mounting bracket at all four corners. Some tractors are equipped with an air control to unlock the fifth wheel. This control allows the driver to unlock the fifth wheel from the cab, using a dash-mounted valve.

55. When servicing a steering column, the first thing a technician should do is: A. adjust toe B. raise and safely support the vehicle C. deactivate the SRS circuit D. drain the power steering fluid

55. The correct answer is C. Before servicing the steering column, make sure the Supplemental Restraint System (SRS) air bag module circuit is fully deactivated. Follow the vehicle manufacturer's recommended procedure to deactivate and remove the air bag module. Always wear safety glasses.

56. The component designed to fit into the pintle hook is called a: A. cross bar B. drawback bar C. towing bar D. drawbar

56. The correct answer is D. The drawbar is designed to fit into the pintle hook, and is used to pull double trailer, triple trailer and truck-trailer combinations. It is important to use a mounting structure on the trailer of sufficient strength to support the rated capacity of the drawbar. Also, the mounting surface must have an ad- equate chamfer to clear the drawbar shank fillet so that the drawbar is flush with its mounting surface.

57. Technician A says the pitman arm is the strongest arm in the steering linkage system. Technician B says the pitman arm is mounted on the steering gear input shaft and is secured by a large nut. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

57. The correct answer is A. The pitman arm is the strongest arm in the steering linkage system. It is made of steel and designed to accept the turning motion of the steering gear output shaft and transfer that motion into the torque needed to move the rest of the steering linkage back-and-forth. It is splined to the steering gear output shaft and secured to the shaft by a large nut.

58. Technician A says that the up-and-down motion of leaf springs is dampened by air bags. Technician B says shock absorbers transfer heat through friction. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

58. The correct answer is B. The up-and-down motion of the leaf spring is dampened by shock absorbers, which contain hydraulic fluid or gas, and pistons with seals in a cylinder. The energy that would otherwise perpetuate the jounce is converted to heat through friction.

59. Runout is defined as: A. the up-and-down or side-to-side movement of the axle. B. the up-and-down or side-to-side movement of the steering. C. the up-and-down or side-to-side movement of the tire or wheel. D. none of the above

59. The correct answer is C. Runout is the up-and-down (radial) and side-to-side (lateral) movement of the tire or wheel when it is rotating. A tire or wheel that is out of round or not running true cannot only contribute to driver discomfort and increased operating costs, it can be a safety concern.

6. A steering gear binds when turning to the left after it has been adjusted. The most likely cause is that the: A. worm bearing preload was set too high B. steering shaft U-joints are sticking C. gearbox was not centered when the lash was adjusted D. recirculating ball nut thrust adjustment is off

6. The correct answer is A. Excessive worm bearing preload would show up as binding as the steering was turned to one extreme and the friction became excessive due to the combination of normal load and too much preload. B is not the answer because sticking U-joints should be apparent and cause rough rotation of the wheel at all steering angles. If either lash or ball nut thrust adjustment was incorrect, the box would either bind at the center or be too loose at the extremes of travel.

60. Technician A says that toe-out-on-turns means that the inside wheel of the vehicle tracks a much larger circle than the outside wheel. Technician B says the relative position of the steering arm joints to the kingpin centerline causes toe-out-on-turns. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

60. The correct answer is B. When a truck is steered into a turn, the outside wheel of the vehicle tracks a much larger circle than the inside wheel. Therefore, the outside wheel must be steered to a somewhat less acute angle than the inside wheel. This difference in angle is often called toe-out-on-turns. The change in angle from toe-in, in the straight-ahead position, to toe-out in the turn, is caused by the relative positions of the steering arm joints to the kingpin centerline and to each other.

61. The flexible couplings attached to steering columns are typically called: A. rib joints B. rag joints C. rack joints D. damper joints

61. The correct answer is B. Most steering columns include -joints or flexible couplings (flexible couplings are typically called rag joints). Normally, a worn or damaged joint can be easily replaced. Most flex couplings are replaceable or rebuildable, and kits are available, but some flexible couplings are fixed parts of the column shaft and can't be replaced separately.

62. Technician A makes toe-in corrections first when aligning a vehicle. Technician B says toe-in is the amount the rear of the front wheels are closer together than the front of the front wheels. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

62. The correct answer is D, neither technician is right. Since toe-in is affected by caster and camber, it should be the last adjustment made. Toe-in is the amount that the front of the front wheels are closer together than they are at the back of the front wheels.

63. Torque arms are designed to: A. keep the axle from twisting B. keep the frame from twisting C. keep suspension jounce at a minimum D. keep the steering from pulling

63. The correct answer is A. Torque arms keep the axle from twisting under the chassis in reaction to torque load from the drivetrain. Movement from side- to-side due to worn torque rod parts will overload the suspension system, resulting in premature wear or even failure of parts.

64. Which of the following are characteristics of a kingpin? A. can be tapered or straight B. connects pitman arm to steering linkage C. cannot be lubricated D. is located in the steering gear

64. The correct answer is A. The kingpin or knucklepin secures the steering knuckle to the axle. It can be either tapered or straight, depending on the manufacturer. Inspection and lubrication of the kingpin must be performed in accordance with the manufacturer's recommended service procedures.

65. The correct term for an axle that is moved slightly to the rear is: A. push back B. knuckle back C. set back D. load back

65. The correct answer is C. Front axles on many trucks have been moved slightly to the rear (or set back) as regulations regarding overall truck length have changed. This has provided longer, smoother riding springs and improved front tire life. The latter has happened because those tires are more consistently loaded and less likely to develop uneven tread wear.

66. Technician A says loose U-bolts will cause the axle to shift. Technician B says when a spring is replaced, the old U-bolts can be reused as long as they are inspected and retorqued in accordance with the vehicle's maintenance schedule. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

66. The correct answer is A. Loose axle -bolts will allow the axle to shift on the springs. Never reuse U-bolts because of the stretching that occurs during normal initial torque, and the impossibility of getting effective clamping force or pull-up torque when they are retorqued.

67. A truck that is being aligned exhibits inaccurate Ackerman geometry from one side to another and is grossly out of specification. Technician A says the problem could be a bent steering arm. Technician B says Ackerman geometry is also known as toe-out steering radius. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

67. The correct answer is C, both technicians are right. If the front-end angles, including toe-in, are set correctly, and the toe-out is found to be grossly different or incorrect, one or both of the steering arms are bent. Ackerman geometry is also known as toe-out or toe-out steering radius. When a truck is steered into a turn, the outside wheel of the vehicle tracks a much larger circle than the inside wheel. Therefore, the outside wheel must be steered to a somewhat less acute angle than the inside wheel. This change in angle from toe-in in the straight-ahead position to toe-out in the turn is caused by the relative position of the steering arm joints to the kingpin centerline and to each other

68. What organization is charged with rating replacement U-bolts? A. STS B. ASE C. SAE D. TMC

68. The correct answer is C. The Society of Automotive Engineers (SAE) grade of bolt is critical. Some manufacturers recommend at least a Grade 7 bolt (115,000 psi yield strength) for highway trucks and Grade 8 (130,000 psi) for off-road. It is important to heed manufacturer's recommendations as to U-bolt replacement and grade.

69. An alternate procedure to inspect steering linkage for looseness is called: A. steering link check B. steering movement check C. dry park check D. lock-to-lock check

69. The correct answer is C. The steering linkage can also be inspected using a procedure called a dry park check.' With the engine off, have an assistant rotate the steering wheel from side-to-side while you inspect the steering linkage joints for looseness. Any side-to-side movement of the steering linkage joints is cause for replacement.

7. Which of these is most likely to cause steering wheel shimmy? A. too much positive caster B. out-of-balance wheels C. air in the power steering system D. low tire pressure

7. The correct answer is B. Out-of-balance wheels cause a high frequency vibration, which shows up in the wheel as shimmy. A is not the answer because caster shows up as too much self-centering action (hard steering). Air in the power steering system causes constantly or intermittently hard steering (lack of hydraulic force). Low tire pressures generally do not cause an uneven force on the steering system, but rather poor tread contact with the road and vague steering or hard steering.

70. Which one of the following is a characteristic of semi-integral power steering gears? A. uses a control valve B. needs more effort to steer C. is self-contained D. none of the above

70. The correct answer is A. Semi-integral units provide hydraulic assistance to the steering unit with the use of a control valve, mounted in conjunction with a manual-type steering gear. The integral steering gear assemblies are self-contained hydraulic units, with the hydraulic pressure developed by an independently-mounted fluid pump driven by the engine.

71. The lower steering shaft U-joint has been replaced on a medium duty truck. While parking the vehicle, the driver notices that the steering is binding when turning the steering wheel from stop to stop. Technician A says the steering shaft U-joints are incorrectly phased. Technician B says that this is this symptom is the winding and unwinding of the steering shaft called Torsional Imbalance. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A or B

71. The correct answer is A. When U-joints are replaced, they must be phased in order to eliminate Torsional Excitation, or winding and unwinding of the steering shaft. U-joint phasing is the relative position to be installed 180-degrees from each other. An incorrectly phased shaft will cause the shaft to bind, producing premature wear of components.

72. Technician A says to begin checking the cab height control valve operation, the linkage should be connected to the valve and the air should be exhausted from the system. Technician B says slight leakage from the height control valve when it is in the neutral position is acceptable. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A or B

72. The correct answer is D, neither technician. When checking the cab height control valve, the linkage must be disconnected from the valve and the air system must be built up to manufacturer's specifications. After the linkage is disconnected, operate the valve in both directions and observe the cab raising and lowering. If the height control valve has air leaks after it has returned to the neutral position, suspect a defective valve.

73. Technician A says lift axles are auxiliary drive axles that help to support additional vehicle weight when needed. Technician B says self-steering lift axles allow for greater truck maneuverability and can be used longer. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A or B

73. The correct answer is B. Some lift axles are self-steering, which allows for greater truck maneuverability for longer periods when the lift axle is lowered. Lift axles are not however drive axles, and are non-powered. Their only function is to assist in handling increased truck loads.

74. Technician A says static balancing is preferred over dynamic balancing. Technician B says material can be inserted into the tire before it is mounted onto the rim for the purpose of balancing the tire/wheel assembly. A. Technician A B. Technician B C. Both A and B D. Neither A or B

74. The correct answer is D, neither technician. Dynamic balancing is the preferred method if long tire life and smooth operation are to be achieved. However, it must be repeated at regular intervals if normal changes in balance are to be corrected. Certain types of materials are marketed for the purpose of balancing the tire by installing a fine grain or liquid material, but they must be installed inside the tire via the valve stem.

75. A truck is equipped with an air-assist steering system. The driver complains that the steering wheel is difficult to turn when maneuvering the vehicle in delivery applications. Technician A says the problem could be with the torque valve. Technician B says the problem could be with the power cylinder. Who is right? A. Technician A B. Technician B C. Both A and B D. Neither A or B

75. The correct answer is C, both technicians. The torque valve senses more than 10-lbs. pressure on the steering wheel (0.04-in. movement) by changing its length very slightly. This, in turn, meters air to a power cylinder. The power cylinder is fastened to the frame and applies force to the wheel arm or tie-rod to assist the driver in turning and holding the steering linkage.

8. Technician A says that steering columns are collapsible to prevent the column from causing serious injury to the driver during a collision. Technician B says that when a steering column has been collapsed, the entire column must be replaced. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

8. The correct answer is C, both technicians are right. Steering columns are made to be collapsible to prevent the column from seriously impacting the driver during a front-end collision. If an accident has occurred, and the steering column has partially collapsed, the entire column must be replaced.

9. A constant buzzing noise comes from the power steering pump. Technician A says the cause could be air in the system. Technician B says the cause could be that the relief valve is stuck in the open position. Who is right? A. Technician A only B. Technician B only C. Both A and B D. Neither A or B

9. The correct answer is A. Fluid passes through the power steering system parts at high flow rates and under high pressures. When it becomes aerated, the bubbles cause rough, uneven flow and consequent noise. When a relief valve sticks open, fluid flows more smoothly (in a less restricted manner than normal). causing no noise but poor power assist instead.