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City~ Guilds

3905-026 DECEMBER 2005 Motor Vehicle Engineering Chassis systems 3

Thursday 8 December 2005 14:00 - 16:00

You should have the following for this examination

• one answer book

• drawing instruments

• non-programmable calculator

General instructions

• Read each question carefully. Simple sketches ordlagrarns may be used to illustrate your answers.

• All questions have equal marks. The maximum marks for each section within a questionare shown.

• Answer all ten questions.

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a) State, in each case, two workshop operations where precautions should be taken to avoid

i) lung irritation

. ii) skin irritation.

c) State one example of a practical task which would require the use of

i) a portable brake efficiency tester

ii) heating equipment.

c) State the meanings of the following term's and give one example of each.

i) Tolerance.

ii) Sliding fit.

2 a) Make a labelled sketch of a diagonally split braking system, with discs at the front and drums at the rear.

b) Figure 1 below shows the layout of a handbrake arrangement.

i) Name and state the purpose of component 3.

ii) Describe briefly, using the numbers for reference, how the system operates when the handbrake lever is applied.

c) State two service checks, other that for wear, which should be carried out to the system shown in Figure 1 .

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,

Figure 1

(4 marks)

(2 marks)

(4 marks)

(5 marks)

(3 marks)

(2 marks) i' ~)

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3 a) State two advantages of an anti-lock braking system (ASS) compared with a conventional system.

b) Figure 2 below shows a view of an ASS system.

i) Name and state the purpose of components A) 3

S) 4.

ii) Explain, in each case,

A) why engine component 8 is connected to component 5 via pipe 6

S) the main symptom which would indicate this pipe had become blocked.

1

5

2

3

8

Figure 2

)

(2 marks)

(4 marks)

(4 marks)

----"-"------------_. __ ... ...--.-~-----.,~.-.---.~-. _ ... - .. "

4 a) Figure 3 below shows a component which is part of a clutch operating mechanism.

i) State the function of this component.

ii) Using the letters for reference, explain how it operates.

b) State the reasons why torque transmitted by a clutch will reduce under each of the following circumstances.

i) No clearance in release cable.

ii) Oil on the centre plate lining.

iii) A centre plate with a mean diameter smaller than specified is fitted.

c) The following data refers to a single plate clutch.

Maximum transmitted torque 25 Nm

Total spring force acting on clutch surfaces 2.5 kN Mean radius 0.16 m

(4 marks)

(3 marks)

Calculate the coefficient of friction (/1).

(3 marks)

Figure 3

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5 a) State one advantage and one disadvantage of an independent rear suspension system, compared to a non-independent type.

b) Figure 4 below shows one side of a rear suspension system. State how each of the following faults will be indicated during a road test.

i) Spring 20 broken.

ii) Bearings 34 excessively worn.

iii) All fluid within damper 18 has leaked out.

iv) Bolts locating components 15 and 16 are loose.

c) The original damper has been removed and the system prepared to receive the new damper. List, in sequence, five significant steps and associated checks involved with replacing damper 18.

(2 marks)

(4 marks)

(4 marks)

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Figure 4

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6 Figure 5 below shows a view of a ball joint which is fitted in the outer end of an upper suspension wishbone.

a) i) State why a joint of this type is necessary in a suspension system.

ii) State two effects on vehicle handling if this joint is excessively worn.

b) Describe a workshop procedure for checking this joint for wear. (Safety precautions are not required in the answer.)

(3 marks) " (3 marks)

Figure 5

c) Figure 6 below shows part of a suspension system.

i) Name the type of system shown.

ii) State the purpose of the splines at each end of component 2.

d) Make a simple sketch to show a procedure for measuring the trim height of a v€hicle.

(2 marks)

(2 marks)

Figure 6

7 The following question refers to automatic gearboxes.

a) State one function of each of the following components.

i) Inhibitor switch.

ii) Torque converter.

iii) Throttle downshift (kick-down) cable. iv) Compound epicyclic gear train.

b) Refer to Table 1 below, which shows the components applied in each gear on a three-speed and reverse automatic gearbox. State the cause of each of the following faults.

i} No drive in 1 st gear (2nd, 3rd and reverse gears operate satisfactorily).

ii) No drive in 3rd or reverse gears (1 st and 2nd gears operate satisfactorily).

iii} No drive in reverse gear (1 st, 2nd and 3rd gears operate satisfactorily).

Gear Engaged Components Applied
1 st gear front clutch and one-way clutch
2nd gear front clutch and front brake band
3rd gear front clutch and rear clutch
.
reverse gear reverse brake band and rear clutch Table 1

8

a) b}

State two reasons why propeller shafts are hollow.

Figure 7 below shows an exploded view of a propeller shaft system and a viscous control unit.

i) State, in each case, why

A) it is essential the universal joints 1 must be refitted with the yokes aligned as shown

B) the viscous control unit 3 is fitted in the drive line.

ii) Show, with the aid of a sketch, one method which could be used to check the shaft 6 for bow.

iii) It is suspected that one of the propeller shaft bearings 4 is excessively worn.

Explain, in each case,

A) how this fault would be indicated during a road test

B) one workshop procedure which would confirm this fault.

(4 marks)

(6 marks)

(2 marks)

(2 marks)

(2 marks)

(4 marks)

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9 a) State two functions of the differential. .

b) Figure 8 below shows a final drive pinion for a live rear axle. State, in each case,

i) the purpose of the collapsible spacer A

ii) what causes the drivingthrust to betransmltted in the direction of arrow B

iii) why the bearing which fits at Cis smallerthan bearing D.

c) Make a simple sketch to show each of the· following types of final drive gear arrangement.

i) Hypoid.

ii) Worm and wheel.

(2 marks)

(4 marks)

(4 marks)

..

A

B

o

Figure 8

10 a) Describe, with the aid of a sketch, one method used to remove a half-shaft from a semi-floating rear axle. Refer to all essential workshop equipment.

b) State two visual checks which should,bemade to a half-shaft toensure it is

serviceable. '"

c) State the purpose ofthe following transmtsslon components

i) limited slip differential ; .

ii) axle casing breather

iii) transfer box.

(5 marks)

(2'rnarks)

(3 marks)

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