Inspect leaf springs, center bolts, clips, pins and bushings, shackles,

insulators, brackets, U-bolts and mounts; determine needed action.

Lesson Plan for
DIT 160-161
Suspension and Steering (Diesel-Medium/Heavy Duty Truck)
Course HS Title: Suspension and Steering (Medium/Heavy Duty Truck) Program:
KCTCS Courses included in HS Title: (Lesson is prepared
for course highlighted.)
KCTCS Course
KCTCS Course Title
No.
Suspension and Steering (Diesel-
DIT 160-161
Medium/Heavy Duty Truck)

Introduction/Context This lesson will instruct the student on how to inspect leaf springs, center bolts,
clips, pins and bushings, shackles, insulators, brackets, U-bolts and mounts, and
determine needed action. Knowledge of these techniques and the skills required
to correct problems associated with this task are necessary for a student to
acquire if they wish to compete for high paying, high skilled jobs in a Diesel
Repair Facility. Entry level technicians need to be able to perform this task to
100% accuracy. Incorrectly performing this task can lead to an accident or create
customer satisfaction issues.
Prepared By School Date:

Lesson
Grade Level No. Students No.IEP's:
Length:

Task

Inspect leaf springs, center bolts, clips, pins and bushings, shackles, insulators, brackets, U-bolts and
mounts; determine needed action.

Objective
Given the proper tools and instruction, the student will be able to inspect leaf springs, center bolts,
clips, pins and bushings, shackles, insulators, brackets, U-bolts and mounts, determine needed
action, and pass a written test covering the task with 100% accuracy.
 Connections:
Skills Standards:
OH 001
OH 002
OH 003
OD 002
OD 003
OD 005
Common Core Technical Standards:
TD-OPS.2
TD-SYS.2
New Common Core State Standards:
RST 11-12 3
N-Q-3
New Generation Science Standards:
HS-PS2-1.
HS-PS3-3

INSTRUCTIONAL MATERIALS/TECHNOLOGY

Teacher Designed Materials and Other Handouts

Textbooks and Workbooks

Author Title/ISBN No. Edition Publisher Pages
Various Suspension and Steering ASE Test Prep T5 Fifth Delmar 23-24

Equipment
Quantity Item Source

Web
Site Author URL

Content/Presentation/Demonstration Outline
Explain that a leaf spring is a spring assembly where the individual leaves are the same width for the
whole length of the assembly. Parabolic springs are assemblies where the leaf width is usually greater
at the center of the spring, and the width decreases toward the outer end of the spring. Tell students
that a taperleaf spring is also classified as a parabolic spring since the leaves are thicker in the center,
and the thickness decreases toward the end of the leaf. Let students know that regardless of what type
of spring assembly is installed on a vehicle, the inspection process is the same.
Tell students that When inspecting the leaf/parabolic spring assemblies, they should look for broken or
shifting leaves in the spring pack, inspect the front and rear shackle spring pins and bushings for wear,
and inspect the U-bolts, spring seats, and top plates for looseness or wear.
Instruct students that the suspension system should be inspected periodically to ensure vehicle safety.
This inspection should be part of a regular maintenance schedule recommended by the truck
manufacturer or truck owner. During a front or rear suspension inspection, tell students to check these
components:
* Inspect the tires for excessive tread wear.
* Check the torque on the wheel nuts, and inspect the wheel rims for damage.
* On rear suspension systems, inspect all torque rods for damage or a bent condition. Inspect all torque
rod bushings for looseness, wear, and deterioration.
* Inspect all spring shackles, bushings, and brackets for looseness. A pry bar may be used to pry
downward on the outer end of the spring to check for looseness in the shackles and bushings.
* Inspect all spring U-bolts for damage and check the torque on the U-bolt nuts. B Inspect the springs for
broken leaves, damaged clamps, broken center bolts, and a sagged condition.
* Inspect all equalizer components for wear.
Tell students to be sure each side of the drive axle housing is positioned on the same location on each
spring. Let them know that a broken center bolt may allow the drive axle to slide backward on the
spring. Loose spring shackles will not break the spring center bolt.
Instruct students that loose front spring U-bolts can break the spring center bolt or leaves between the
U-bolts. A broken leaf spring center bolt can cause axle shifting leading to premature toe-like tire wear
and steering pull. Also, if the spring assembly is replaced, tell them to always replace the U-bolts. U-bolt
threads stretch during initial installation and scale and rust buildup may prevent improper pull-up torque
and insufficient clamping force.
Inform students that if a defective spring assembly is identified, the following recommendations should
be considered:
* Whenever one spring leaf is broken, all of the other leaves in the assembly have been overloaded and
running under increased stress. Consideration should be made to the age and condition of the other
leaves prior to repair.
* If one spring leaf is broken, and the remaining leaves are deemed serviceable, it is acceptable to
replace only the broken leaf However, tell them it is advisable to replace the same leaf in the other
spring pack on that axle to ensure both spring assemblies remain matched regarding load carrying
capacity, rate of deflection, and ride height characteristics.
* If two or more leaves are broken in the spring pack, it is recommended that the entire spring assembly
be replaced.
* If the spring assembly on one side of the vehicle is being replaced, it is advisable to replace both
spring assemblies across that axle.

Applications/Practice
1 Refer to content

Evaluation and feedback Prior to Testing or Lab Work

Objective 1. / Formative assessment / Instructor will observe students as they practice the procedure
to assure correct procedure and safety practices are being followed. A checklist will be utilized to
1 chart student progress on the task. Questioning techniques will be utilized as necessary to
demonstrate student comprehension / Adaptations and/or accommodations for special needs
students will be added if required.

STUDENT ASSESSMENT: (Assess student progress with performance criteria.)

Objective 1 / Summative assessment / written test questions on stated objective / adaptation and / or
1 accommodations for special needs students will be added if required
IMPACT--Reflection/Analysis of Teaching and Learning: (How did students progress in relation to the
state objectives? Was the instruction successful? Analyze samples of student work particularly that
which is unsatisfactory, for the purpose of planning further instruction.)

REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial
planning and/or during the teaching learning process.)