COMPETENCY-BASED LEARNING MATERIAL

SECTOR: AUTOMOTIVE AND LAND TRANSPORT

QUALIFICATIONS:
AUTOMOTIVE SERVICING NC I

UNIT OF COMPETENCY:
PERFORM PERIODIC MAINTENANCE OF STEERING SYSTEM

MODULE TITLE:
PERFORMING PERIODIC MAINTENANCE OF STEERING SYSTEM

ITECH COMPUTER ACADEMY INC.

where class and distinction matter
Malasiqui, Pangasinan

HOW TO USE THIS MODULE

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 Welcome to the Module “Performing Periodic Maintenance of Steering System”.
This module contains training materials and activities for you to complete.

The unit of competency “Perform Periodic Maintenance Of Steering System”

contains knowledge, skills and attitudes required for an Automotive Servicing NCI.

You are required to go through a series of learning activities in order to complete each
of the learning outcomes of the module. In each learning outcome there are Information
Sheets, Operation Sheets, and Activity Sheets. Follow these activities on your own and
answer the Self-Check at the end of each learning activity.

If you have questions, don’t hesitate to ask your teacher/trainer for assistance.

Recognition of Prior Learning (RPL)

You may already have some of the knowledge and skills covered in this module
because you have:
- been working for some time
- already completed training in this area.

If you can demonstrate to your teacher that you are competent in a particular skill or
skills, talk to him/her about having them formally recognized so you don’t have to do the
same training again. If you have a qualification or Certificate of Competency from previous
trainings show it to your trainer. If the skills you acquired are still current and relevant to this
module, they may become part of the evidence you can present for RPL. If you are not sure
about the currency of your skills, discuss it with your trainer.

After completing this module ask your trainer to assess your competency. Result of
your assessment will be recorded in your competency profile. All the learning activities are
designed for you to complete at your own pace.

Inside this module you will find the activities for you to complete followed by
relevant information sheets for each learning outcome. Each learning outcome may have
more than one learning activity.

REMEMBER TO:

 Work through all the information and complete the activities in each section.
 Talk to your trainer and agree on how you will both organize the Training of
this unit. Read through the module carefully. It is divided into sections, which cover all
the skills, and knowledge you need to successfully complete this module.
 Read information sheets and complete the self-check. Suggested references are
included to supplement the materials provided in this module.
 Use the Self –Check and Job Sheets at the end of each section to test your own
progress.
 Talk to more experience workmates and ask for their guidance. When you feel
confident that you have had sufficient practice, ask your instructor to evaluate you. The
results of your assessment will be recorded in your Progress chart and Accomplishment
Chart.
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 LIST OF COMPETENCIES

No. Unit of Competency Module Title Code

1. Performing Pre-Delivery
Perform Pre-Delivery Inspection ALT723372
Inspection
2. Perform Periodic Maintenance Performing Periodic
of Automotive Engine Maintenance of ALT723373
Automotive Engine
3. Perform Periodic Maintenance Performing Periodic
Of Drivetrain Maintenance Of Drivetrain ALT723374
4. Perform Periodic Maintenance Performing Periodic
Of Brake System Maintenance Of Brake ALT723375
System
5. Perform Periodic Maintenance Performing Periodic
Of Suspension System Maintenance Of ALT723376
Suspension System
6. Perform Periodic Maintenance Performing Periodic
Of Steering System Maintenance Of Steering ALT723377
System

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 MODULES OF INSTRUCTION

QUALIFICATION AUTOMOTIVE SERVICING NC I

UNIT OF Perform Periodic Maintenance of steering system
COMPETENCY
MODULE TITLE Performing Periodic Maintenance of steering system
MODULE DESCRIPTOR This module deals with performing Periodic maintenance
of steering system.
NOMINAL DURATION 24 HOURS
LEARNING OUTCOMES
At the end of this module you must be able to:
LO 1. Perform pre- periodic maintenance of steering system
LO 2. Apply periodic maintenance procedures
LO 3. Perform work to completion

LEARNING OUTCOME SUMMARY

LEARNING OUTCOME 1 Perform pre-periodic Maintenance of steering system

CONTENTS:
1. Explain suspension system fundamentals
2. Identify the tools and equipment and their correct usage base on suspension system
service manual.
3. Apply safety practices in workplace
ASSESSMENT CRITERIA:
1. Job requirements are determined based on steering system repair order.
2. Servicing information is sourced from service manual.
3. Tools, equipment and materials are prepared based on steering system repair order.
4. Hazards and risks associated in the workplace are managed following OSHS.
5. Protective covers are installed based on standard operating procedure
PREREQUISITE: Basic and Common Competencies
METHODOLOGY:
 Self-paced learning
 Individual practice
ASSESSMENT METHOD:
 Observation
 Written Test

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 1: Perform pre-periodic Maintenance of

steering system
Learning Activity/ Guide Special Instruction
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 Read Information sheet 6.1-  Perform all activities required.
1. Explain suspension system  You must get a rating of 80 to 100%. If
fundamentals. you get below 80% rating, go over the
 Answer Self-Check 6.1-1 on same activities.
Explain suspension system  If you get the required rating, proceed to
fundamentals. the next activities.
 Compare Answers to Answer
Key
 Perform Operation sheet 6.1-1
Replacing rack and pinion
assembly
 Read information sheet 6.1-2  Perform all activities required.
Identify the tools and  You must get a rating of 80 to 100%. If
equipment and their correct you get below 80% rating, go over the
usage base on suspension same activities.
system service manual.  If you get the required rating, proceed to
 Answer Self-Check 6.1-2 on the next activities.
Identify the tools and
equipment and their correct
usage base on suspension
system service manual.
 Compare Answers to Answer
Key
 Read Information Sheet 6.1-3  Perform all activities required.
Apply safety practices in  You must get a rating of 80 to 100%. If
workplace you get below 80% rating, go over the
 Answer Self-Check 6.1-3 on same activities.
Apply safety practices in  If you get the required rating, proceed to
workplace. the next activities.
 Compare Answers to Answer
Key

INFORMATION SHEET 6.1-1

Explain suspension system fundamentals

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Steering is a system of components, linkages, etc. that allows a vehicle to follow a desired
course. An exception is the case of rail transport, by which rail tracks combined with railroad
switches (provide the steering function. The primary purpose of the steering system is to
allow the driver to guide the vehicle.

The steering system of your car is everything from the steering wheel to the steering shaft,
rack, and pinion (also known as the gearbox), all the way to the linkage which connects to the
wheels themselves.

It is also known as the steering system, in automobiles, the steering wheel, gears, linkages,
and other components are used to control the direction of a vehicle’s motion.

The system contains a hydraulic booster, which operates when the engine is running and
supplies most of the necessary force when the driver turns the wheel.

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Types of a Steering system:
Today, the majority of cars are built with either of these two extremely popular steering
wheel systems:

1. The rack and pinion system

Components: Steering Wheel, Steering shaft, pinion, rack, tie rod, stub axle

The rack and pinion steering system is the most commonly used steering system on today’s
date. Found in most cars, smaller trucks, and SUVs, its operation mechanism is fairly simple.
The rack-and-pinion system works to transform the rotational motion of the steering wheel
into linear motion which in turn works to rotate the wheels of your car. The steering wheel is
attached to a circular gear called the steering pinion which is attached to the rack through
teeth-like structures. The tie rod and the stub axle attach the rack to the front wheels. This
system turns the big rotations of the steering wheel into small and accurate turns of the wheel.

Modern technology has also enabled the integration of power-steering into the equation.
Power steering gives an extra push to the steering system with the help of either hydraulic
power or electric power (an electric engine or an engine-driven pump is added for this).
Found in many cars today, especially utility vehicles and trucks, power steering makes
driving more seamless, as it drastically cuts the need for manual work. A power steering only
assists the driver when force Is being exerted by the driver on the steering wheel. The
addition of a power steering into the rack-and-pinion steering system makes navigation
easier, especially on jammed roads.

2. Recirculating Ball Steering System

Components: Steering wheel, steering shaft, ball nut rack, recirculating ball bearings, sector
gear, pitman arm, worm gear

The recirculating ball system is usually present in old cars. The mechanism through which it
works is slightly different from the rack and pinion system. The steering system consists of
two parts. The first part is a hollow (threaded hole) metal block with gear teeth on the
outside. The gear teeth are connected to the sector gear which enables the pitman arm to
move. Inside the hollow metal box, is a threaded rod, very similar to a bolt, that is connected
to the steering wheel. When the driver rotates the steering wheel, the bolt turns too. However,
unlike a regular bolt that would twist further into the metal box, the threaded rod is fixed
inside the metal box. Therefore, the entire metal box rotates when the steering wheel is
rotated. This in turn, rotates the gears that turn the wheels.

The bolt doesn’t directly engage the threads in the metal box. Instead, the threads are filled
with re-circulating ball bearings. These re-circulate through the gear as it turns. The ball
bearings reduce friction, as well as wear and tear in the gear. Other than that, they enable the
reduction of slop in the gear, which is an unnecessary movement of the gears. Without the
presence of the re-circulating balls, the steering wheel would feel loose, since the teeth would
disconnect from each other from moment to moment. Just like the rack and pinion steering
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system, the efficacy of the re-circulating ball steering system is also enhanced by the power
steering which does its work by supplying a high-pressure fluid to one side of the metal
block.

Parts of the Steering system:

The parts of the Steering system that are available are:

 Ball Joints
 Bushings
 Sway Bar Links
 Center Links
 Idler Arms/Pitman Arms
 Rack and Pinion Units
 Tie Rod Ends/Sleeves
 CV Joints/Boots
 CV Axle Half Shafts
 Shock Absorbers
 Struts/Cartridges
These are the parts of the steering system

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Components of a Steering system:
The components of a steering system are listed below. They are:

1. Steering wheel
2. Steering column or shaft
3. Steering gear
4. Drop arm or pitman arm
5. Ball joints
6. Drag link
7. Steering arm
8. Stub axle
9. Left spindle and kingpin
10. Left tie rod arm

1. Steering wheel:
The steering wheel is the control wheel to steer a vehicle by the driver. It contains a traffic
indicator switch, light switch, wiper switch, etc. It is also called a driving wheel or a hand
wheel is a type of steering control in vehicles.

Steering wheels are used in most modern land vehicles, including all mass-production
automobiles, as well as buses, light, and heavy trucks, and tractors.

2. Steering column or shaft:

The Steering column also known as the shaft is fitted inside the hollow steering column.
When the steering wheel is turned, the steering shaft will also be rotated. Due to this, the
motion is transmitted to the steering box.

The steering column is located at the top of the steering system and attaches directly to
the steering wheel. The steering column then attaches to the intermediate shaft and universal
joints.

3. Steering gear:
The pitman’s arm is splined to the steering gearbox rocker arm at one end and the other end is
connected to the drag link by a ball joint.

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The steering gearbox contains the gears that transmit the driver’s steering inputs to
the steering linkage that turns the wheels, and it multiplies the driver’s steering changes so
that the front wheels move more than the steering wheel.

4. Drop arm or pitman arm:

When the steering wheel is turned right or left the pitman transmits the motion it receives
from the steering gearbox to the tie rod. A “drop pitman arm” is used to correct
the steering when a vehicle has a suspension lift.

5. Ball Joints:
The ball joints are spherical bearings that connect the control arms to the steering knuckles.
The bearing stud is tapered and threaded and fits into a tapered hole in the steering knuckle.
A protective encasing prevents dirt from getting into the joint assembly.

6. Drag link:
The drag link converts the sweeping arc of the steering arm to linear motion in the plane of
the other steering links. “The drag link connects the pitman arm to the steering arm, or in
some applications, it connects to the tie rod assembly.

7. Steering arm:
The steering arm is an arm for transmitting the turning force from the steering gear to the
drag link, especially of an automotive vehicle.

The basic function of the steering system is to allow the driver to safely and
precisely steer the vehicle. Beyond this, the steering system also provides a way to reduce
driver effort by making the act of steering the vehicle easier.

8. Stub axle:
When the steering wheel is rotated, the motion is transmitted to the pitman’s arm through the
gearbox. This motion is transmitted to the drag link. Drag link transfers this movement to
stub axle which rotates about kingpin. This turns the right wheel.

9. Left spindle and king arm:

In automotive suspension, a steering knuckle is that part that contains the wheel hub or
spindle and attaches to the suspension and steering components. It is variously called a
steering knuckle, spindle, upright, or hub, as well.
The wheel and tire assembly attach to the hub or spindle of the knuckle where the tire/wheel
rotates while being held in a stable plane of motion by the knuckle/suspension assembly.

10. Left tie rod arm:

The right- and left-side tie rods are connected to each other by a center link, which is also
mounted to the Pitman’s arm on the steering gear and the idler arm on the passenger side of
the vehicle.
Rack and pinion steering are currently the most predominant of the
two steering linkage systems.

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 Function of a Steering system:

The function of a steering system is to convert the rotary movement of the steering wheel in
the driver’s hand into the angular turn of the front wheels on road.

Additionally, the steering system should provide a mechanical advantage over front-wheel
steering knuckles, offering the driver an easy turning of front wheels with minimum effort in
any desired direction.

The steering system provides the directional change in the movement of an Automobile and
maintains a position as per the driver’s decision without much strain on him.

This system converts the rotary movement of the steering wheel into the angular movement
of the front wheels. It multiplies the driver’s effort by mechanical advantage, enabling him to
turn the wheels easily.

The important function of the steering system is as follows:

1. With the help of the steering system, the driver can control the vehicle however he
wants
2. The steering provides stability to the vehicle on the road.
3. It minimizes tyre wear and tear.
4. It prevents road shocks from reaching to the driver.
5. The steering provides self-rightening effect after taking a turn.

How a Car Steering System Works?

The steering system will convert the rotary motion of the steering wheel into the angular turn
of the front wheels.

 Steering wheel rotates the steering column.

 The steering gearbox is fitted to the end of this column. Therefore, when the wheel is
rotated, the cross shaft in the gearbox oscillates.
 The cross shaft is connected to the drop arm. This arm is linked by means of a drag
link to the steering arms.
 Steering arms on both wheels are connected by the tie rods to the drag link.
 When the steering wheel is operated the knuckle moves to and fro, moving the
steering knuckle are connected to each other.
 One end of the drag link is connected to the tie rod. The other end is connected to the
end of the drop arm.

The Purpose of a Steering System

For effective control of the vehicle throughout its speed range with safety and without much
effort to the driver on different types of road surfaces, proper steering is necessary. For
proper performance and useful service of the automobile, it is necessary that the moving
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vehicle should be under the perfect control of the driver. Thus the control of the automobile is
done by means of a steering system that provides directional changes to the moving
automobile.

3 Types of Power Steering Systems

Early steering systems were simple mechanical mechanisms. Today’s power steering is much
more intricate. Without power steering, just about every vehicle — from those classic mid-
20th century behemoths to today’s smaller, denser front-wheel-drive cars, crossovers and
SUVs — would be difficult to steer.

For more than a half-century, hydraulic power steering ruled the roads. No longer. Now
hybrid electro-hydraulic and fully electric power steering systems are commonplace. Such
systems can even vary the assistance applied to the steering system, depending on driving
conditions

How do the Three Power Steering Systems Differ?

All three power steering systems perform the same important function, but they execute it
differently. A hydraulic system uses mechanically pumped high pressure fluid, an electro-
hydraulic system uses an electric motor to pressure fluid, and an electric system uses an
electric motor and sensors. The end result is the same: You can easily turn the steering wheel
under all conditions. Fully electric power steering systems save about one mile per gallon,
require less maintenance and are more reliable that a hydraulic system.

Hydraulic Power Steering

his system uses pressurized power steering fluid, supplied by the power steering pump, to
decrease steering effort. An engine-driven accessory drive or serpentine belt turns on the
pump and directs high-pressure power steering fluid via the high-pressure hose to the input
side of the power steering gear-control valve.

High pressure acting on the control valve assists the driver when turning the front wheels.
Power steering fluid is stored in a reservoir. Proper fluid level in the reservoir is maintained
when the fluid returns from the steering gear at much lower pressure. Hydraulic power
steering systems continuously pump fluid and are susceptible to engine speed — high
revolutions per minute equal high pressure output, lower revolutions per minute equal low
pressure output. To maintain constant pressure, a power steering pump uses a bypass valve to
maintain constant pressure no matter what the engine speed.

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Electro-Hydraulic Power Steering

These systems employ a brushless electric motor to drive the hydraulic power steering pump
instead of an engine driven accessory drive or serpentine belt. This system operates the same
and provides the same feel of a conventional hydraulic power steering system.

System Configuration
Electro-Hydraulic power steering system
1. Hydraulic assist
(greater reduction ratio than with gears, etc.)
2. 12V power supply
(Since large reduction ratio possible, DC-DC converter for voltage step-up is not needed)
3. Small cylinder diameter (50mm)
(Motor does not need to be mounted on rack, since a large reduction ratio is obtained)

Electric Power Steering or Motor-Driven Power Steering

This system eliminates hydraulics and pressurized fluid from the system. When the driver
turns the steering wheel, a brushless bi-directional permanent magnet motor connected to the
steering gear or steering column turns the front wheels. Sensors detect which way the steering
wheel is turned to assist the movement of the steering gear in the correct direction.

No matter what kind of system you have, power steering only acts on the steering gear when
the driver turns the wheel.

EPS powered directly by motor

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1. Motor power directly assists steering
(large reduction ratio not obtainable with worm gear or ball screw)
2. 42V power supply
(small reduction ratio means DC-DC converter needed to provide power)
3. Large motor diameter(110mm)
(to provide sufficient power, a large motor must be mounted on the rack shaft)

Advantages of Electric Power Steering

Hydraulic power steering systems are complex, heavy, require maintenance and take up a lot
of space. Electric power steering uses considerably fewer parts.

Using steering angle and steering torque sensors, plus sophisticated software, engineers can
adjust the amount of assist, but also how the steering feels to the driver by reproducing
different road feel characteristics for different driving conditions. And hydraulic power
steering uses 90 percent more engine power than electric power steering.

Because an electric power steering system draws significantly less power from the engine, it
greatly improves fuel economy and reduces tailpipe emissions. And removing a drive pulley
and belt from the engine reduces wear and tear. This will prolong the engine’s life and help
reduce costly repairs.

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Functions and Basic Principles The steering system, along with the suspension system, allows
the driver to safely and easily control the vehicle’s direction while driving. To accomplish
these goals the steering system works with components of the suspension to provide for the
turning movement of the wheels. In addition to connecting the driver to the wheels, the
steering system also provides feedback to the driver from the front tires. This feedback, called
road feel, is used by the driver to determine how the vehicle is handling. The Steering System
The steering system consists of the components that allow the driver to turn the front wheels
of the vehicle, and for a few vehicles, provides for a limited amount of steering by the rear
wheels. The overall function of the steering system has not changed much since the earliest
days of the automobile.

Functions of the Steering System. The most basic function of the steering system is to allow
the driver to safely and precisely steer the vehicle. Beyond this, the steering system also
provides a way to reduce driver effort by making the act of steering the vehicle easier. The
components of the steering system also absorb some of the road shock before it gets to the
driver. Very little has changed in the operation of the steering system or in some of the
components since the earliest automobiles. The things that have changed primarily have to do
with increased ease and effectiveness of operation and longer-lasting components that require
less maintenance.

Steering Columns and Shafts. The basic operation and function of the steering column has
not changed very much; the column gives the driver the ability to control the direction of the
front wheels and provides some leverage to make steering a little easier. Early steering
columns contained the steering shaft, steering wheel, and often had the choke and ignition
timing advance controls mounted on them for easy access. An early model car’s steering
wheel and column are shown in Figure 8-1. Today’s columns still perform the same steering
functions and still have controls for other systems or components mounted to them for easy
access by the driver, as shown in Figure 8-2. New vehicles sold in the United States are also
required to have a collapsible steering column to help prevent driver injury in the event of a
front-end collision. Steering shafts transmit the motion of the steering wheel from the column
to the steering gear. There is usually at least one coupler or joint between the column and
gearbox to allow for changes in angles and to
reduce binding when turning the wheel. Figure 8-3
shows how a steering shaft links the steering
column and steering gearbox.

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 The popular rack and pinion steering system

In most cars, small trucks and SUVs on the road today, there is a rack and pinion steering
system. This converts the
rotational motion of the
steering wheel into the linear
motion that turns the wheels
and guides your path. The
system involves a circular gear
(the steering pinion) which
locks teeth on a bar (the rack).
It also transforms big rotations
of the steering wheel into
small, accurate turns of the
wheels, giving a solid and direct feel to the steering.

3 Critical Components in a Power Steering System

 The Pump. The power steering pump's job is to pressurize the hydraulic fluid. ...
 The Pump Pulley. Like a multitude of other components beneath your hood, the power
steering pump receives its own power from your car's engine. ...
 The Rotary Valve.

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The return of four-wheel steering
Beyond the swivel of the front wheels, some cars have a steering system which affects all
four. This has traditionally been exclusive to sporty or luxury models, but there’s a growing
trend towards the feature in more affordable cars.

A four-wheel steering control unit sits behind the rear axle of the car and affects the rear
wheels as needed. Car wheels turn in opposite directions at low speeds, but at high speeds,
turning all four wheels in concert helps to maintain stability and prevent fishtailing.

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Wheel Alignment

Wheel alignment is defined as the correct adjustment of the pivot axes controlling the
movement of the wheels.

The wheels alignment, therefore, refers to the correct positioning of the front wheels and
steering mechanism for the promotion ease of steering, reducing tyre wear to a minimum as
well as providing directional stability to the vehicle.

Proper aligned front wheels result in.

 Steering comfort.
 Uniform wear of tyres.
 Minimum energy consumption.
 Minimum vibrations.
 No wheel wobbling.
 Reduce the driver effort to turn the vehicle.
 To achieve self-centring of the wheel after turning.
 To achieve directional stability of the vehicle while running.

To obtain a good alignment it is necessary to understand the following factors,

1. Camber (Wheel rake or Camber angle).

2. Caster.
3. King Pin inclination.
4. Toe-in.
5. Toe-out.
Camber

The angle between the centerline of the tyre and the vertical line, when viewed from the front
of the vehicle, is known as camber. When the wheels are tilted outwards at the top is called
positive camber, and if titled inward at the is called negative camber. An equal camber angle
is provided on both the
front wheels.

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With the positive camber, wheels become verticle under load on the tyre will have full
contact with the road, hence the tyre wear will be uniform. If the positive camber is excessive
then tyres outer edge will rear will wear out faster. If the negative camber is excessive the
tyres inner edge will wear out faster.

Unequal camber on both the front wheels will result in wheels vibration at low speed. Older
models have considerable camber. Present-day cars use improved design and materials they
have very little camber. The camber should not exceed 2°. The camber on modern vehicles is
adjusted by means of an eccentric cam in the control arm shaft.

Caster

The Kingpin axis or steering axis may be tilted forward or backward from the vertical line.
This tilt is known as Caster. Caster Angle: The caster angle is the angle formed by the
forward or backward tilt of the steering axis from the vertical when viewed from the side of
the wheel.

A backward tilt is known as a positive caster and a forward tilt is known as a negative caster.
If the caster is not equal on both sides it will cause the vehicle to pull to the side of the wheel
having a lesser caster angle. The caster angle in modern vehicles varies from 2° to 8°.

Purposes of Caster

 To maintain directional stability and control.

 To increase steering stability.
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  Reduce drives effort to turn the vehicle.

King Pin Inclination

The angle between the vehicle line and center of the kingpin or steering axis, when viewed
from the front of the vehicle, is known as Kingpin inclination.

The Kingpin inclination in modern cars varies from 7° to 8°. It must be equal on both sides. It
is greater on one side than the other, the vehicle will tend to pull to the side having a greater
angle.

The main functions of Kingpin inclination are as follows,

 It helps in self-centring of wheels after taking a turn.

 To provide directional stability.
 It reduces steering effort.

Toe-in

Front wheels are slightly tilted inward at the front of the distance between the front wheels at
the front (A) is less than the distance at its rear (B) measured at the height of the hub level
and at the center of the wheel tread.

The difference in its distance is ‘Toe-in’ (B-A). it is usually 2 to 3 mm. The purpose of the
toe-in is to overcome the bad effect of camber. The toe-in is adjusted by tie-rod ends.

Toe-out

Whenever the vehicle is taking a turn with Ackerman steering geometry the inner wheel turn
more degrees than the outer wheel so that the perpendiculars of all four wheels at a point

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when produced. This point is called the instantaneous center so that all the wheels roll very
easily without scuffing.

Types of steering system depending upon the leverage

There are two types of steerings depending upon the leverage provided between the road
wheel and the steering wheel and also the number of shocks and vibrations transmitted from
the road wheels to the steering wheels, namely,

1. Reversible steering.
2. Irreversible steering.
Reversible Steering

Reversible steering is one in which the gear ratio is 1:1. For example bicycle or scooter
steering. In gear case, any angular movement of the handle causes the same angular
movement to the wheel and the wobbling or vibrations of the wheel are faithfully transmitted
to the steering handle. This arrangement is suitable for only bicycles, motorcycles, scooters,
etc.

Irreversible Steering

Here gear reduction between and wheels and the steering wheel is very high. Ex-In road
rollers it is about 40:1.

Here very high gear reduction is necessary. Because the load carried on the wheel is very
high. With this type of steering, there will not be any transmission of notion due to vibration
of the wheel from road wheels to steering wheels.

Steering Gears

If the steering wheel is connected directly to the steering linkage it would require a great
effort to move the front wheels. Therefore, to assist the driver a reduction system is used. The
Steering gear is a device for converting the rotary motion of the steering wheel into the
straight-line motion of the linkage with a mechanical advantage. The steering gears are
enclosed in a box called the steering gearbox.

Types of Steering Gears

Following are the eight important steering gears:

1. Recirculating ball steering gear.

2. Rack and pinion steering gear.
3. The Worm and sector steering gear.
4. Worm and roller steering gear.
5. Worm and ball bearing nut steering gear.
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 6. Cam and roller steering gear.
7. The Cam and peg steering gear.
8. Cam and double lever steering gear.

1. Recirculating Ball Steering Gear

The circulating ball gear is similar to the worm and ball bearing not steering gear. The balls
are contained in half nut and a transfer tube. As the cam or worm rotates, the balls pass from
one side of the nut to the transfer tube to the opposite side. As the nut cannot turn, and
movement of the balls along the track of the cam carries the nut allowing with it and rotates
the rocker shaft.

2. Rack and Pinion Steering Gear

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In the rack and pinion steering gear, a pinion is mounted on the end of the steering shaft. It
engages with the rack which has a ball joint at each end to allow for the rise and fall of the
wheels.

The roads connect the ball joints to the stub excels. The rotary movement of the steering
wheel turns the pinion which moves the rack sideways. This movement of the rack is
converted into wheels.

In the rack and pinion steering gear, a pinion is mounted on the end of the steering shaft. It
engages with the rack which has a ball joint at each end to allow for the rise and fall of the
wheels.

The roads connect the ball joints to the stub excels. The rotary movement of the steering
wheel turns the pinion which moves the rack sideways. This movement of the rack is
converted into wheels.

3. Worm and Sector Steering Gear

In the worm and sector steering gear, the worm on the end of the steering shaft meshes with a
sector mounted on a sector shaft. When the worm is rotated by rotation of the steering wheel,
the sector also turns rotating a sector shaft. Its motion is transmitted to the wheel through the
linkage.

Note that 6the sector shaft is also known as pitman arm shaft, pitman shaft, roller shaft,
steering arm shaft, cross shaft.

4. Worm and Roller Steering Gear

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In the worm and roller steering gear, a two-toothed roller is fastened to the sector or roller
shaft so that it meshes with the threads of the worm gear or shaft at the end of the steering
shaft or tube.

When the worm shaft is turned is it causes the roller to move in an arc so as to rotate the
roller shaft, and at the same time turn on the pin connecting it to the shaft. The roller is
mounted on a ball bearing.

The worm shaft is mounted on a bearing designed to resist both radial and end thrust. This
type of steering gear is widely used in American passenger cars.

5. Worm and Ball Bearing Nut Steering Gear

In the worm and ball bearing nut steering gear, a ball nut is mounted on the worm of the
steering shaft. The worm and the nut have mating spiral grooves in which steel balls circulate
to provide a frictionless drive between the worm and nut.

Two sets of balls are used, with each set operating independently of others. A ball return
guide is attached to the outer surface of the nut. When the steering shaft is turned to the left or
right, the ball nut is moved up and down by the balls which roll between the worm and nut.

A sector gear mounted on the sector shaft meshes with the ball nut, so that it gets motion by
the ball nut.

6. Cam and Roller Steering Gear

In the cam and roller steering gear, a cam

meshes with the roller. As the cam rotates,
the roller is compelled to follow the cam and
in doing so causes the rocker shaft to rotate,
thus moving the drop arm.
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The contour of the cam is designed to mesh with the arc made by the roller so maintaining a
constant depth of mesh and evenly distributing the load and wear on the mating parts.

7. Cam and Peg Steering Gear

8. Cam and Double Lever Steering Gear

In the cam and double lever steering gear, a special worm called a cam, replaces the worm
used in the two types of worm and sector steering gear and worm and roller steering gear.

The cam is cylindrical in shape, its actuating part being a groove of the variable pitch made
narrower at the center than at the end. This provides non-reversibility in the center part of the
cam where most of the car steering takes place.

The twin levers are mounted on the cross

shaft and are located so that the stubs
engage the cam from the side. When the
cam is turned, the stubs move along the
cam groove to cause the lever to swing
through an arc and thus turning the cross
shaft.

SELF CHECK 6.1-1

ENUMERATION:

Test 1.To obtain a good alignment

what are the following you need to
check?

1.

2.

3.

4.

5.

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Test II- What are the functions of steering system?

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 ANSWER KEY 6.1-1

Test -1.

1. Camber

2. Caster

3. King pin inclination

4. Toe-in

5. Toe-out

Test –II

1. With the help of the steering system, the driver can control the vehicle however he
wants.
2. The steering provides stability to the vehicle on the road.
3. It minimizes tyre wear and tear.
4. It prevents road shocks from reaching to the driver.
5. The steering provides self-rightening effect after taking a turn.

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 OPERATION SHEET 6.1-1

REPLACING THE RACK AND PINION ASSEMBLY

1 . Raise and support the vehicle with jack stands under the frame rails behind the front
wheels after blocking a rear wheel.

2 . Disconnect the steering joint between the steering column and rack and pinion assembly.
Do not allow the column or wheel to turn while the joint is disconnected. The image above
shows a steering universal coupler on the left and a rag joint on the right. I'm pointing to what
is called a pinch bolt in the image on the left. This is all that needs to be removed to separate
the column and input shaft. Both bolts in the right-hand image need to come out, after which
you need to use a small chisel to open the bottom of the joint. Use a large screwdriver to pry
the joint away from the steering rack input shaft.

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3. Using a flare nut wrench as pictured, remove the two power-steering hoses on the rack and
pinion assembly. Make sure the pipe does not spin with the fitting. Soak it with penetrating
oil and rock it back and forth if it does.

4. Measure the distance between the bellows boot to the inside of the tie rod locknut on both
sides of the vehicle. I also like to measure the distance between the inside edge of the tires.
Write these numbers down.

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5. Use an open-end wrench to crack the tie rod locknut loose. Remove the cotter pin in the
castellated nut (I use pliers or wire cutters) and remove the nut with a wrench. Smack the side
of the steering knuckle with a hammer to loosen the tie rod stud.

6. At this point, the location and ease of access on what needs to be disconnected can vary
among vehicles. Here's an example of what needs to be done on a Toyota Tundra after
removing the outer tie rod ends. No. 1 is the steering shaft connector. No. 2 is the two power-
steering fluid lines from the pump. No. 3 is the three mounting bolts.

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7. Remove the old rack and pinion and compare it with the replacement unit to ensure proper
fitment. There may be mounts that you will need to transfer from the old unit to the new one,
such as the Camry rack pictured above.

8. Install the new rack and pinion assembly and loosely install the rack mount bolts.

9. Reinstall the fluid lines, replacing any O-rings with those supplied with the new rack.
Reconnect the steering column to the input shaft. Torque the rack mount bolts.

1 0 . Reinstall the tie rod ends using the measurements from above and tighten the locknut.
Torque the tie rod nut and install the new cotter pin in the tie rod castellated nut. Do not reuse
old cotter pins.

11. Use the measurement from above and adjust the tie rods. Tighten the tie rod locknuts.

12.Replace the wheels and lower the vehicle.

13.If your vehicle is equipped with power steering, you will need to know how to bleed the
power-steering pump after allowing all the old fluid to drain out during the replacement
process. Refill the pump until the level no longer goes down. Check your owner's manual or
repair manual to determine which fluid you need. Some use power-steering fluid, while
others use automatic transmission fluid. Start the engine and slowly turn the wheel to both
left and right lock positions, refilling the reservoir as needed. This bleeds, or purges the air
from the system. You may hear a growling sound until all the air bubbles have been purged
or bled from the system.

14. Get an alignment.

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 Performance Criteria Checklist 6.1-1

CRITERIA YES NO

Did I……

1. Gathered instruction and relevant materials?

2. Read and followed manufacturer’s manual safety precautions?

3. Perform job requirements for steering system?

INFORMATION SHEET 6.1-2

Preparing specified tools, equipment and materials for steering system

maintenance

Tools and Safety Safe working practices include proper tool use and care, following the
proper repair procedures, staying focused on the task, and taking the time to perform your
work properly. Several special tools are used to service the steering system, and using them
properly will allow you to work safely and efficiently. Tools As with all aspects of
automotive repair, the steering system has its own special tools used to diagnose and service
its components. Although basic hand tools are used for most repairs, some jobs cannot be
safely or correctly performed without the right tools. Tools for Steering Service. The
following figures show and explain the uses of many of the tools you will use when working
on the suspension system. To remove the steering wheel for repairs on the steering column or
to remove the clockspring for the airbag, a steering wheel puller kit like that in Figure 1-1 is
used. When replacing ball joints, a ball joint press is often required. Figure 1-2 shows an
example of a ball joint press kit. Replacing a power steering pump requires removing and
reinstalling the pulley on many vehicles. The kit shown in Figure 1-3 is used to remove and
press the pulley onto the power steering pump. Removing a Pitman arm requires a Pitman
arm puller, shown in Figure 1-4. This is because the Pitman shaft in the gearbox is tapered,
making the fit between the arm and the shaft very tight.

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 FIGURE 1-1

FIGURE 1-2

FIGURE 1-3

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 FIGURE 1-4

FIGURE 1-5

Replacing inner tie rod ends on rack and pinions requires special tie rod sockets shown in
Figure 1-5. Some of these sockets fit specific tie rods, like the upper socket in Figure 1-5. The
other tie rod socket is a universal tool, used on a variety of rack and pinions. Removing outer
tie rod ends from the steering knuckle without damaging the tie rod is accomplished by using
a tie rod separator, like the tool shown in Figure 1-6. Checking drive b tension often requires
using a belt tension gauge, like that illustrated in Figure 1-7

FIGURE 1-6

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 FIGURE 1-7

Ratchet and sockets

A ratchet is a mechanical device that allows

continuous linear or rotary motion in only one
direction while preventing motion in the opposite
direction. Ratchets are widely used in machinery
and tools. The word ratchet is also used informally
to refer to a ratcheting socket wrench

Lug wrench

A large cross-shaped wrench used to remove

the lug nuts so that the tire may then be removed.

Wrenches

A wrench or spanner is a tool used to provide

grip and mechanical advantage in applying
torque to turn objects—usually rotary fasteners,
such as nuts and bolts—or keep them from turning.
In the UK, Ireland, Australia, and New Zealand
spanner is the standard term. Wikipedia

Torque wrench
A torque wrench is a tool used to apply a specific
torque to a fastener such as a nut, bolt, or lag screw.
It is usually in the form of a socket wrench with special
internal mechanisms. A torque wrench is used where
the tightness of screws and bolts is crucial. Wikipedia

Screwdrivers

A screwdriver is a tool, manual or powered, used for

driving screws. A typical simple screwdriver has a handle

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and a shaft, ending in a tip the user puts into the screw
head before turning the handle. Wikipedia

Pliers are a hand tool used to hold objects firmly,

possibly developed from tongs used to handle hot metal in
Bronze Age Europe. They are also useful for bending and
compressing a wide range of materials. Wikipedia.

Flare nut wrench

A wrench or spanner is a tool used to provide grip

and mechanical advantage in applying torque
to turn objects—usually rotary fasteners, such as nuts
and bolts—or keep them from turning. In the UK,
Ireland, Australia, and New Zealand spanner
is the standard term. Wikipedia

Drip pan

Vehicle-specific repair manual

A handbook containing instructions and specifications

for the maintenance and repair of a certain vehicle.

Jack and stands

a stand whose height may be adjusted and which

is used to support an automobile that has been
raised by a jack.

Safety glasses

Goggles, or safety glasses, are forms of

protective eyewear that usually enclose or
protect the area surrounding the eye in order
to prevent particulates, water or chemicals from
striking the eyes. They are used in chemistry
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laboratories and in woodworking. They are often
used in snow sports as well, and in swimming. Wikipedia

Hammer

A hammer is a tool, most often a hand tool,

consisting of a weighted "head" fixed to a long
handle that is swung to deliver an impact to a small
area of an object. This can be, for example, to drive
nails into wood, to shape metal,
or to crush rock. Wikipedia

Small chisel

Tape measure/Push-pull rule

A tape measure or measuring tape is a flexible

ruler used to measure size or distance. It consists
of a ribbon of cloth, plastic, fibre glass, or metal
strip with linear measurement markings. It is a
common measuring tool. Wikipedia

Power-steering fluid (check your owner's manual for the correct

fluid)
Power steering fluid is the hydraulic fluid used in the steering
system to create a hydraulic link between the steering wheel and
the front wheels. ... It suppresses foaming and prevents corrosion in
the power steering gear and steering pump, which keeps vehicles
working optimally.

SELF CHECK 6.1-2

ENUMERATION: Give atleast 10 tools,equipment, and

materials needed for power steering maintenance.

1.

2.

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3.

4.

5.

6.

7.

8.

9.

10.

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 INFORMATION SHEET 6.1-3

Apply safety practices in workplace

Safe Work Practices.

When you are performing work on the steering system, you may have to service components
that require special handling procedures. The following are some general safe work practices
for working on the steering system.

• Use the proper tool for the job.

• Do not use steel hammers, punches, or chisels on other steel components.

• Disable the airbag system before performing any repairs to the steering column.

• Always identify all special procedures and warnings in the service information for the
system on which you are working.

• Do not attempt to service a system or component if the correct tools are not available.

• Ensure that the vehicle is properly raised and secure before attempting to work.

• Do not attempt to open or repair any airbag or airbag system component.

• Follow the manufacturer’s service procedures exactly when working on the airbag system.

 When removing the steering wheel, always use the correct puller for safe removal.
 When removing tie rods, they may be stuck in place. Always use the correct tools to
remove tie rods(e.g., pickle fork)
 Many steering systems parts are heavy. Make sure you have the correct tools and jacks to
reduce any safety hazard.
Steering Columns

Cars and trucks use the steering column for more than holding the steering wheel in place.
Even though the primary purpose of the column is for the driver to control the direction of the
front wheels, there is often much more going on than just steering. There are many switches
and controls mounted on the column; the steering wheel contains the driver’s airbag, and
many cars and trucks now have electrically operated power steering assist that works through
the steering column. Because of the combination of controls located around the column, it is
common to perform repairs on either the column or some of its extraneous components.

Safety precautions when servicing steering system of a vehicle

 Always ensure that you use a power steering system analyzer gauge before starting
any trouble shooting in a steering wheel.

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  Do not clean the power steering with a high pressure wash since this may force
contaminations into the gear which may end up destroying the bearings and the seals

 When changing the transmission fluids from one to another, always ensure to entirely
flush the steering system and do not mix them since this may result to seal
deterioration

 Prior to placing the vehicle back into service, always ensure to remove air out the
steering system.

 Never hold the steering wheel for more than 15 seconds when the system is at full
turn since it may build some heat that may end up destroying the system components.

Other general safety measures to adhere to in the workshop

 Do not smoke in the workshop area

 Do not take alcoholic or intoxicating drinks in the workshop

 No unnecessary running or playing around the workshop

 Treat hot surfaces and liquids with caution to avoid burns

 Be careful when using sharp pointed tools to avoid injuries

 Always take off clothes soaked with fuel or other chemicals or oil. These can become
irritants to your skin

 Always take off jewelry(especially necklaces, rings and bangles)before working to avoid
electrocution and/or entanglement with rotating and moving parts
 R

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 SELF CHECK 6.1-3

ENUMERATION: Give atleast 10 Safety practices in a workplace

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

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 ANSWER SHEET 6.1-3

See answers on information sheet 6.1-3 in any order.

MODULES OF INSTRUCTION

QUALIFICATION AUTOMOTIVE SERVICING NC I

UNIT OF Perform Periodic Maintenance of steering system
COMPETENCY
MODULE TITLE Performing Periodic Maintenance of steering system
MODULE DESCRIPTOR This module deals with performing Periodic maintenance
of steering system.
NOMINAL DURATION 24 HOURS
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LEARNING OUTCOMES
At the end of this module you must be able to:
LO 1. Perform pre- periodic maintenance of steering system
LO 2. Apply periodic maintenance procedures
LO 3. Perform work to completion

LEARNING OUTCOME SUMMARY

LEARNING OUTCOME 2 Apply periodic maintenance procedures

CONTENTS:
1. Explain suspension system fundamentals
2. Identify the tools and equipment and their correct usage base on suspension system
service manual.
3. Apply safety practices in workplace
ASSESSMENT CRITERIA:
1. Job requirements are determined based on steering system repair order.
2. Servicing information is sourced from service manual.
3. Tools, equipment and materials are prepared based on steering system repair order.
4. Hazards and risks associated in the workplace are managed following OSHS.
5. Protective covers are installed based on standard operating procedure
PREREQUISITE: Basic and Common Competencies
METHODOLOGY:
 Self-paced learning
 Individual practice
ASSESSMENT METHOD:
 Observation
 Written Test

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 2: Apply periodic maintenance procedures

Learning Activity/ Guide Special Instruction
 Read Information sheet 6.1-  Perform all activities required.
1. Explain suspension system  You must get a rating of 80 to 100%. If
fundamentals. you get below 80% rating, go over the
 Answer Self-Check 6.1-1 on same activities.
Explain suspension system  If you get the required rating, proceed to
fundamentals. the next activities.
 Compare Answers to Answer
Key
 Perform Operation sheet 6.1-1
Replacing rack and pinion
assembly
 Read information sheet 6.1-2  Perform all activities required.
Identify the tools and  You must get a rating of 80 to 100%. If
CBLM ON DRIVING NC Date Developed: Document No.
II August 1, 2024
PERFORM PERIODIC
Developed by: Issued by: Page 43 of 46
MAINTENANCE OF
MARIA DOLORES L. ITECH COMPUTER
STEERING SYSTEM
SISON ACADEMY INC.
 equipment and their correct you get below 80% rating, go over the
usage base on suspension same activities.
system service manual.  If you get the required rating, proceed to
 Answer Self-Check 6.1-2 on the next activities.
Identify the tools and
equipment and their correct
usage base on suspension
system service manual.
 Compare Answers to Answer
Key
 Read Information Sheet 6.1-3  Perform all activities required.
Apply safety practices in  You must get a rating of 80 to 100%. If
workplace you get below 80% rating, go over the
 Answer Self-Check 6.1-3 on same activities.
Apply safety practices in  If you get the required rating, proceed to
workplace. the next activities.
 Compare Answers to Answer
Key

CBLM ON DRIVING NC Date Developed: Document No.

II August 1, 2024
PERFORM PERIODIC
Developed by: Issued by: Page 44 of 46
MAINTENANCE OF
MARIA DOLORES L. ITECH COMPUTER
STEERING SYSTEM
SISON ACADEMY INC.
 MODULES OF INSTRUCTION

QUALIFICATION AUTOMOTIVE SERVICING NC I

UNIT OF Perform Periodic Maintenance of steering system
COMPETENCY
MODULE TITLE Performing Periodic Maintenance of steering system
MODULE DESCRIPTOR This module deals with performing Periodic maintenance
of steering system.
NOMINAL DURATION 24 HOURS
LEARNING OUTCOMES
At the end of this module you must be able to:
LO 1. Perform pre- periodic maintenance of steering system
LO 2. Apply periodic maintenance procedures
LO 3. Perform work to completion

LEARNING OUTCOME SUMMARY

LEARNING OUTCOME 3 Perform work to completion

CONTENTS:
1. Explain suspension system fundamentals
2. Identify the tools and equipment and their correct usage base on suspension system
service manual.
3. Apply safety practices in workplace
ASSESSMENT CRITERIA:
1. Job requirements are determined based on steering system repair order.
2. Servicing information is sourced from service manual.
3. Tools, equipment and materials are prepared based on steering system repair order.
4. Hazards and risks associated in the workplace are managed following OSHS.
5. Protective covers are installed based on standard operating procedure
PREREQUISITE: Basic and Common Competencies
METHODOLOGY:

CBLM ON DRIVING NC Date Developed: Document No.

II August 1, 2024
PERFORM PERIODIC
Developed by: Issued by: Page 45 of 46
MAINTENANCE OF
MARIA DOLORES L. ITECH COMPUTER
STEERING SYSTEM
SISON ACADEMY INC.
  Self-paced learning
 Individual practice
ASSESSMENT METHOD:
 Observation
 Written Test

LEARNING EXPERIENCES

LEARNING OUTCOME NO. 3: Perform work to completion

Learning Activity/ Guide Special Instruction

 Read Information sheet 6.1-  Perform all activities required.
1. Explain suspension system  You must get a rating of 80 to 100%. If
fundamentals. you get below 80% rating, go over the
 Answer Self-Check 6.1-1 on same activities.
Explain suspension system  If you get the required rating, proceed to
fundamentals. the next activities.
 Compare Answers to Answer
Key
 Perform Operation sheet 6.1-1
Replacing rack and pinion
assembly
 Read information sheet 6.1-2  Perform all activities required.
Identify the tools and  You must get a rating of 80 to 100%. If
equipment and their correct you get below 80% rating, go over the
usage base on suspension same activities.
system service manual.  If you get the required rating, proceed to
 Answer Self-Check 6.1-2 on the next activities.
Identify the tools and
equipment and their correct
usage base on suspension
system service manual.
 Compare Answers to Answer
Key
 Read Information Sheet 6.1-3  Perform all activities required.
Apply safety practices in  You must get a rating of 80 to 100%. If
workplace you get below 80% rating, go over the
 Answer Self-Check 6.1-3 on same activities.
Apply safety practices in  If you get the required rating, proceed to
workplace. the next activities.
 Compare Answers to Answer
Key

CBLM ON DRIVING NC Date Developed: Document No.

II August 1, 2024
PERFORM PERIODIC
Developed by: Issued by: Page 46 of 46
MAINTENANCE OF
MARIA DOLORES L. ITECH COMPUTER
STEERING SYSTEM
SISON ACADEMY INC.