2000 auto prep guide

8/13/2019 2000 Auto Prep Guide

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T HE O FFICIAL

ASE P REPARATION G UIDE

ASE

AUTOMOBILETECHNICIAN

TESTS

Includes Light Vehicle/Compressed Natural Gas and Exhaust Systems!


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ASE AUTOMOBILE P REPARATION GUIDE P AGE 1

ASE Automobile Preparation Guide

Table of Contents

Overview ----------------------------------------------------------------- 1-5

Automobile Tests ----------------------------------------------------- 6-67 Engine Repair (Test A1) ----------------------------------------------- 6 Automatic Transmission/Transaxle (Test A2) -------------------- 14 Manual Drive Train and Axles (Test A3) -------------------------- 19 Suspension and Steering (Test A4) --------------------------------- 26

Brakes (Test A5) ------------------------------------------------------ 35 Electrical/Electronic Systems (Test A6) --------------------------- 42 Heating and Air Conditioning (Test A7) --------------------------- 52 Engine Performance (Test A8) -------------------------------------- 59

Alternate Fuels Test ------------------------------------------------ 68-73

Light VehicleCompressed Natural Gas (Test F1)-------------- 68

Specialty Tests ------------------------------------------------------- 74-78 Exhaust Systems (Test X1) ------------------------------------------ 74

Industry Training --------------------------------------------------- 79-96


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OVERVIEW

In t roduct ion This Preparation Guide is intended to help automobile technicians study for the ASEcertification tests. It was written by the same people who develop and assemble the

actual ASE tests and, therefore, should be very useful for reviewing technicalknowledge and seeking additional reference material.

ASE voluntary certification is a means through which technicians can provetheir abilities to themselves, to their employers, and to their customers. By passingASE tests you will earn the most valuable credential available to automotivetechnicians. Because the tests are tough, youll have the satisfaction of proving toyourself that you are among the elite in your profession. Whats more, thesecredentials are recognized throughout the nation.

Certified technicians promote customer trust and improve the image of theindustry. And trust and professionalism are the first steps to a better, more prosperousbusiness.

ASE encourages you to take the tests and to join the proven pros who wear theASE Blue Seal of Excellence.

How Do I Bec om e Cer ti fied? There are eight tests in the Automobile Technician certification series. If you passone or more tests, and have at least two years of hands-on working experience inautomotive repair, then you will become certified as an ASE Automobile Techni-cian. If you pass all eight tests in the series and meet the experience requirement, youwill earn the certificate of Master Automobile Technician. (Appropriate vocationaltraining may be substituted for up to one year of work experience.)

If you fail a test, you may take it again during any scheduled test administrationin which it is offered. And remember, you are the only one who will receive your tests

scores; results will not be given over the phone nor will they be released to anyonewithout your written permission.

ASE tests and certifies technicians in the following areas of specialization (theTest Content section of this booklet has a detailed list of content areas covered in eachtest):


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P AGE 2 ASE A UTOMOBILE P REPARATION G UIDE

OVERVIEW (CONTINUED)

Automobile Tests Engine Repair (Test A1) Automatic Transmission/Transaxle (Test A2) Manual Drive Train and Axles (Test A3) Suspension and Steering (Test A4) Brakes (Test A5) Electrical/Electronic Systems (Test A6) Heating and Air Conditioning (Test A7) Engine Performance (Test A8)

Alternate Fuels Light VehicleCompressed Natural Gas (Test F1)

Specialty Tests

Exhaust Systems (Test X1)

You will become an Undercar Specialist when you pass this test and meet thefollowing requirements. You must be currently certified (including the two-yearexperience requirement) in the ASE Suspension and Steering (A4) and Brakes (A5)areas BEFORE you will be permitted to register and take the X1 test. If your A4 and/ or A5 certification has expired, you may NOT register for the X1 test until after youhave renewed your A4 and A5 certification.

ASE also offers certification in Medium/Heavy Truck, Truck Equipment,School Bus, Collision Repair/Refinish, Engine Machinist, and Advanced Levelspecialties. Separate Preparation Guides are available.

For additional information on ASE testing, you can receive the Registration

Booklet by mailing the coupon contained on the back cover of this booklet. The Registration Booklet will give you the test dates, locations and other importantinformation about the certification program. It also contains a registration form to usein signing up for the tests.

Who Writes the Que stion s? The questions, written by service industry experts familiar with all aspects of automobile repair, are entirely job-related. They are designed to test the skills that

you need to know in servicing automobiles; theoretical knowledge is not covered.Each question has its roots in an ASE item-writing workshop where service

representatives from automobile manufacturers (domestic and import), aftermarketparts and equipment manufacturers, working technicians and vocational educatorsmeet in a workshop setting to share ideas and translate them into test questions. Eachtest question written by these experts must survive review by all members of thegroup. The questions are written to deal with practical problems of diagnosis andrepair experienced by technicians in their day-to-day work.


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From there, all questions are pre-tested and quality-checked on a national

sample of technicians. Those questions that meet ASE standards of quality andaccuracy are included in the scored sections of the tests; the rejects are sent back to the drawing board or discarded altogether.

Each certification test is made up of between forty and eighty multiple-choicequestions. The testing sessions are 4 hours and 15 minutes, allowing plenty of timeto complete several tests.

Ho w Do I Prepare fo r the ASE Tests?

Become familiar with test content and question format: The Test Specifications inthis booklet contain a summary description of the content covered by each test. TheSpecifications Task Lists describe the actual work performed by technicians in eachspecialty area. Together, these form a blueprint for writing and assembling theASE tests.

Please note that each question on the test is keyed, or linked, to a particular task or set of tasks in the task list. Therefore, a review of the task lists, with an eye to

judging whether you know how to perform each task listed, will provide you valuableinformation as you prepare for the tests.

There are five types of multiple-choice questions on the tests, each of which isincluded in the sample questions in this booklet. Note the different instructions foreach question type.

Be sure to read each question carefully, (twice, if necessary) so that youunderstand exactly what is being asked. Each question tests a specific diagnostic or repair problem and has only one best answer.

To summarize, we suggest the following steps be taken:

Step 1. Study the content list for each test you will attempt.

Step 2 . Carefully read the task list for each area.

Step 3. Go over the sample questions to become familiar with eachquestion type. This is very important.

Step 4. Review steps 1 through 3 and identify the skill area(s) where

you need additional study.Types o f Kno wled ge M easured By the Tests The types of knowledge and skills you will need to know to pass the tests are asfollows:

Basic technical knowledge: Tests your knowledge of what is in a system andhow the system works, and what are the proper procedures and precautions to befollowed in making repairs and adjustments.


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Correction or repair knowledge and skill: Tests your understanding andability to apply generally accepted repair procedures and precautions in assembly,disassembly, and reconditioning operations; and in making major inspections andadjustments. Also tests ability to use shop manuals and precision tools of the trade.

Testing and diagnostic knowledge and skill: Tests your ability to recognizerepair problems and to use generally available measurement and testing equipmentto diagnose the difficulty. Also tests your ability to trace the effects of a particularcondition and find the cause of a particular set of symptoms.

If you are an experienced and competent technician, a careful review of thisbooklet, and additional brush-up on those areas in which you are weakest, is all youshould need to pass the ASE tests.

Befo re The Tests Try to be well-rested for the tests so you will be alert and efficient. Have three or foursharpened soft-lead (#2) pencils and an eraser with you; pencils will not be furnishedat the test center. If you wish to pace yourself, bring a watch, some testing rooms maynot have clocks. Finally, be sure to bring along your test center admission ticket and

some form of identification.At the Test Cen ter When you reach the test center, wait in the assigned area until the proctor begins thetest administration. He or she will instruct you in filling out the answer folder and willtell you the amount of time allotted for each test.

Once the test has begun, keep track of time. Do not spend too long on any onequestion. If a question is difficult, mark the answer that you think is correct and put

a check by it in the test book. Then go on to the next question. If you finish beforethe allotted time, you may go back to the questions that you checked.

It is to your advantage to answer every question. Do not leave any answersblank. Your score will be based on the number of correct answers that you give.

Test Content and Samp le Quest io ns The following material is designed to help technicians prepare for the ASE certifi-cation tests.

Each section begins with the Test Specifications, which will list the maincategories covered on that particular test and the number of test questions andpercentage of the test devoted to each topic.

The Task List describes the work activities a technician should be able toperform in each technical area covered on that test. This list was developed byworking technicians and technical experts from across the country and will providea valuable check list of what to study for the test.


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These task descriptions offer detailed information to technicians preparing forthe test and to persons who may be instructing technicians. The task lists may alsoserve as guidelines for question writers, reviewers, and test assemblers.

It should also be noted that the number of questions in each content area may notequal the number of tasks listed. Some of the tasks are complex and broad in scopeand may be covered by several questions. Other tasks are simple and narrow in scopeand one question may cover several tasks. The main objective in listing the tasks isto describe accurately what is done on the job, not to make each task correspond toa particular test question.

Sample questions follow. Although these same questions will not appear onactual tests, they are in the same format as actual test questions. All five types of multiple-choice questions used on the ASE tests are represented here. Note thedifferent instructions for some questions.

Answers to the sample questions are located at the end of each section. The firstquestion and answer also include a brief explanation to help you learn how to analyzepossible answers.


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TEST SPECIFICATIONSENGINE REPAIR (TEST A1)

Content Questions PercentageArea in Test of Test

A. General Engine Diagnosis 17 24%B. Cylinder Head and Valve Train

Diagnosis and Repair 18 26%C. Engine Block Diagnosis and Repair 18 26%D. Lubrication and Cooling Systems

Diagnosis and Repair 9 13%E. Fuel, Electrical, Ignition, and Exhaust

Systems Inspection and Service 8 11%

Total 70 1 100%

1Note: The test could contain up to ten additional questions that are included forstatistical research purposes only. Your answers to these questions will not affect yourscore, but since you do not know which ones they are, you should answer all questionsin the test. The five-year Recertification Test will cover the same content areas as thoselisted above. However, the number of questions in each content area of the RecertificationTest will be reduced by about one-half.


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TASK LISTENGINE REPAIR (TEST A1)

Reading this task list will allow you to focus your preparation on those subjects whichneed your attention. If you feel comfortable with your knowledge about a particulartask, you are probably prepared for questions on that subject. If, on the other hand,you have any doubts, this is where you should spend your study time. Any good textbook or service manual will give you the information you need. Also, you shouldconsider how many questions will be asked in each content area.

A. General Engine Diagnosis (17 questions)1. Verify drivers complaint and/or road test vehicle; determine necessary action.2. Determine if no-crank, no-start, or hard starting condition is an ignition system,

cranking system, fuel system, or engine mechanical problem.3. Inspect engine assembly for fuel, oil, coolant, and other leaks; determine necessary

action.4. Listen to engine noises; determine necessary action.5. Diagnose the cause of excessive oil consumption, coolant consumption, unusual

engine exhaust color, odor, and sound; determine necessary action.6. Perform engine vacuum tests; determine necessary action.7. Perform cylinder power balance tests; determine necessary action.8. Perform cylinder compression tests; determine necessary action.9. Perform cylinder leakage tests; determine necessary action.

B. Cylinder Head and Valve Train Diagnosis and Repair (18 questions)1. Remove cylinder heads, disassemble, clean, and prepare for inspection according to

manufacturers procedures.2. Visually inspect cylinder heads for cracks, gasket surface areas for warpage,

corrosion, and leakage, and check passage condition.3. Inspect and test valve springs for squareness, pressure, and free height comparison;

replace as necessary.4. Inspect valve spring retainers, rotators, locks, and valve lock grooves.5. Replace valve stem seals.6. Inspect valve guides for wear; check valve guide height and stem-to-guide clear-

ance; determine needed repairs.7. Inspect valves; resurface or replace according to manufacturers procedures.8. Inspect and resurface valve seats according to manufacturers procedures.9. Check valve face-to-seat contact and valve seat concentricity (runout).

10. Check valve spring installed (assembled) height and valve stem height; service valveand spring assemblies as necessary.

11. Inspect pushrods, rocker arms, rocker arm pivots, and shafts for wear, bending,cracks, looseness, and blocked oil passages; repair or replace as required.

12. Inspect and replace hydraulic or mechanical lifters/lash adjusters.


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A1 TASK LIST (CONTINUED)

13. Adjust valves on engines with mechanical or hydraulic lifters.14. Inspect and replace camshaft drives (includes checking gear wear and backlash,

sprocket and chain wear, overhead cam drive sprockets, drive belts, belt tension,tensioners, and cam sensor components).

15. Inspect and measure camshaft journals and lobes.16. Inspect and measure camshaft bore for wear, damage, out-of-round, and alignment;

repair or replace according to manufacturers specifications.17. Time camshaft(s) to crankshaft.18. Reassemble and install cylinder heads and gaskets; replace and tighten fasteners

according to manufacturers procedures.C. Engine Block Diagnosis and Repair (18 questions)

1. Disassemble engine block and clean and prepare components for inspection.2. Visually inspect engine block for cracks, corrosion, passage condition, core and

gallery plug holes, and surface warpage; determine necessary action.3. Inspect and repair damaged threads where allowed; install core and gallery plugs.4. Inspect and measure cylinder walls; remove cylinder wall ridges; hone and clean

cylinder walls; determine need for further action.5. Visually inspect crankshaft for surface cracks and journal damage; check oil passage

condition; measure journal wear; check crankshaft sensor reluctor ring (whereapplicable); determine necessary action.

6. Inspect and measure main bearing bores and cap alignment and fit.7. Install main bearings and crankshaft; check bearing clearances and end play;

replace/retorque bolts according to manufacturers procedures.8. Inspect camshaft bearings for unusual wear; remove and replace camshaft bearings;

install camshaft, timing chain, and gears; check end play.9. Inspect auxiliary (balance, intermediate, idler, counterbalance, or silencer) shaft(s)

and support bearings for damage and wear; determine necessary action.10. Inspect, measure, service, repair, or replace pistons, piston pins, and pin bushings;

identify piston and bearing wear patterns that indicate connecting rod alignmentproblems; determine necessary action.

11. Inspect connecting rods for damage, alignment, bore condition, and pin fit; deter-mine necessary action.

12. Inspect measure, and install or replace piston rings; assemble piston and connectingrod; install piston/rod assembly; check bearing clearance and sideplay; replace/ retorque fasteners according to manufacturers procedures.

13. Inspect, reinstall, or replace crankshaft vibration damper (harmonic balancer).14. Inspect crankshaft flange and flywheel mating surfaces; inspect and replace

crankshaft pilot bearing/bushing (if applicable); inspect flywheel/flexplate for cracksand wear (includes flywheel ring gear); measure flywheel runout; determinenecessary action.

15. Inspect and replace pans, covers, gaskets, and seals.16. Assemble engine parts using formed-in-place (tube-applied) sealants or gaskets.D. Lubrication and Cooling Systems Diagnosis and Repair (9 questions)

1. Perform oil pressure tests; determine necessary action.2. Disassemble, inspect, measure, and repair oil pump (includes gears, rotors, housing,

and pick-up assembly), pressure relief devices, and pump drive; replace oil filter.


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3. Perform cooling system tests; determine necessary action.4. Inspect, replace, and adjust drive belts, tensioners, and pulleys.5. Inspect and replace engine cooling and heater system hoses.6. Inspect, test, and replace thermostat, by-pass, and housing.7. Inspect coolant; drain, flush, and refill cooling system with recommended coolant;

bleed air as required.8. Inspect and replace water pump.9. Inspect, test, and replace radiator, heater core, pressure cap, and coolant recovery

system.10. Clean, inspect, test, and replace fan (both electrical and mechanical), fan clutch, fan

shroud, air dams and cooling related temperature sensors.11. Inspect, test, and replace auxiliary oil coolers.

E. Fuel, Electrical, Ignition, and Exhaust Systems Inspection and Service (8 questions)1. Inspect, clean or replace fuel and air induction system components, intake manifold,

and gaskets.2. Inspect, service or replace air filters, filter housings, and intake ductwork.3. Inspect turbocharger/supercharger; determine necessary action.4. Test battery; charge as necessary.5. Remove and replace starter.6. Inspect and replace positive crankcase ventilation (PCV) system components.7. Visually inspect and reinstall primary and secondary ignition system components;

time distributor.8. Inspect, service, and replace exhaust manifold.


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1. Technician A says that part X shown above is used to rotate the valve spring.Technician B says that part X shown above is used to correct installed springheight. Who is right?

(A) A only (C) Both A and B(B) B only (D) Neither A nor B

Question #1 Explanation:

Technician As statement is wrong. Valve spring rotators are located on the topof the valve spring and usually take the place of the spring retainer.

Technician Bs statement is correct. Whenever the valves face and seat areground, the valve will move farther up into the cylinder head port. This relocatesthe valve stem end farther from the top of the head, increasing the distancebetween the underside of the valve spring retainer and the valve spring seat.Increasing the valve springs installed height also reduces its tension. To correctinstalled spring height and restore spring tension to its original spec, a shim of theproper thickness can be inserted between the cylinder head and the spring.

Therefore the answer to this question is (B).

2. A compression test shows that one cylinder is too low. A leakage test on thatcylinder shows that there is too much leakage. During the test, air could be heardcoming from the tail pipe. Which of these could be the cause?

(A) Broken piston rings (C) A bad exhaust gasket(B) A bad head gasket (D) An exhaust valve not seating

SAMPLE QUESTIONSENGINE REPAIR (TEST A1)

Questions:


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3. Technician A says that main bearing oil clearance can be checked with plasti-gage. Technician B says that main bearing oil clearance can be checked with afeeler gauge. Who is right?


4. An engine is using too much oil. Technician A says that worn valve guides couldbe the cause. Technician B says that tapered cylinder walls could be the cause.Who is right?


5. To raise the seat contact on the valve face show above, the seat should be groundwith a:

(A) 60 stone (C) 30 stone(B) 45 stone (D) 15 stone

6. A compression test has been made on an in-line 4-cylinder engine. Cylinders 2and 3 have readings of 10 psi. Cylinder 1 has a reading of 140 psi and cylinder4 has a reading of 145 psi. Technician A says that these readings could be causedby a blown head gasket. Technician B says that these readings could be causedby wrong valve timing. Who is right?


A1 SAMPLE QUESTIONS (CONTINUED)

FACESEAT (45 )


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7. To determine piston-to-cylinder wall clearance, the diameter of the piston shownabove should be measured at:

(A) W. (B) X. (C) Y. (D) Z.

8. Which of these would most likely cause a fuel-injected engine to have low fuelpressure?

(A) A clogged fuel filter(B) A clogged fuel injector(C) A restricted fuel return line(D) A stuck-closed fuel pressure regulator

9. Technician A says that the setup shown above can be used to check cylinder taper.Technician B says that the setup can be used to check cylinder out-of-round. Whois right?

(A) A only (C) Both A and B

(B) B only (D) Neither A nor B


X

Z

Y

W

X

Y

Z

W


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10. The pressure and volume tests on a mechanical fuel pump are both below specs.Technician A says that an air leak in the fuel line between the tank and pump couldbe the cause. Technician B says that a plugged fuel tank pick up filter could bethe cause. Who is right?


Question 11 is not like the ones above.

It has the word LEAST. For this question, look for the choice that would LEASTLIKELY cause the described situation. Read the entire question carefully beforechoosing your answer.

11. The LEAST likely cause of a bent push rod is:

(A) excessive engine rpm.(B) a sticking valve.(C) excessive valve guide clearance.(D) a worn rocker arm stud.


Answer Key:

1. B 2. D 3. A 4. C 5. B 6. A 7. C 8. A 9. C 10. C 11. C


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TEST SPECIFICATIONSAUTOMATIC TRANSMISSION /TRANSAXLE (TEST A2)


A. General Transmission/TransaxleDiagnosis 25 50%1. Mechanical/Hydraulic Systems (11)2. Electronic Systems (14)

B. Transmission/Transaxle Maintenanceand Adjustment 5 10%

C. In-Vehicle Transmission/Transaxle Repair 9 18%D. Off-Vehicle Transmission/Transaxle

Repair 11 22%1. Removal, Disassembly, and Assembly (3)2. Gear Train, Shafts, Bushings,

Oil Pump, and Case (4)3. Friction and Reaction Units (4)

Total 50 1 100%

1Note: The test could contain up to ten additional questions that are included forstatistical research purposes only. Your answers to these questions will not affect yourscore, but since you do not know which ones they are, you should answer all questionsin the test. The five-year Recertification Test will cover the same content areas as thoselisted above. However, the number of questions in each content area of the Recertification

Test will be reduced by about one-half.


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TASK LISTAUTOMATIC TRANSMISSION /TRANSAXLE (TEST A2)

Reading this task list will allow you to focus your preparation on those subjects whichneed your attention. If you feel comfortable with your knowledge about a particulartask, you are probably prepared for questions on that subject. If, on the other hand,you have any doubts, this is where you should spend your study time. Any good text

book or service manual will give you the information you need. Also, you shouldconsider how many questions will be asked in each content area.

A. General Transmission/Transaxle Diagnosis (25 questions)1. Mechanical/Hydraulic Systems (11 questions)

1. Evaluate drivers concern and road test vehicle to verify mechanical/hydraulicsystem problems; determine necessary action.

2. Diagnose noise and vibration problems; determine necessary action.3. Diagnose unusual fluid usage, type, level, and condition problems; determine

necessary action.4. Perform pressure tests; determine necessary action.5. Perform stall tests; determine necessary action.6. Perform torque converter clutch (lock-up converter) mechanical/hydraulic system

tests; determine necessary action.7. Diagnose mechanical and vacuum control systems; determine necessary action.

2. Electronic Systems (14 questions)1. Evaluate drivers concern and road test vehicle to verify electronic system problems;

determine necessary action.2. Perform pressure tests on transmissions equipped with electronic pressure control;

determine necessary action.3. Perform torque converter clutch (lock-up converter) electronic system tests;

determine necessary action.4. Diagnose electronic transmission control systems using appropriate test equipment;

determine necessary action.5. Verify proper operation of starting and charging systems; check battery, connec-

tions, and vehicle grounds.

B. Transmission/Transaxle Maintenance and Adjustment (5 questions)1. Inspect, adjust, and replace manual valve shift linkage, transmission range sensor/ switch, and park/neutral position switch (inhibitor/neutral safety switch).

2. Inspect, adjust, and replace cables or linkages for throttle valve (TV), kickdown, andaccelerator pedal.

3. Replace fluid and filter(s); verify proper fluid level.C. In-Vehicle Transmission/Transaxle Repair (9 questions)

1. Inspect, adjust, and replace vacuum modulator, valve, lines, and hoses.2. Inspect, adjust, repair, and replace governor cover, seals, sleeve/bore, valve, weight,

springs, retainers, and gear.


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3. Inspect and replace external seals and gaskets.4. Inspect and repair or replace extension housing, bushing, and driveshaft yoke.5. Check condition of engine cooling system; inspect, test, and flush or replace

transmission cooler, lines, and fittings.6. Inspect and replace speedometer/speed sensor drive gear, driven gear, and retainers.7. Inspect valve body mating surfaces, bores, valves, springs, sleeves, retainers,

brackets, check balls, screens, spacers, and gaskets; replace as necessary.8. Check and adjust valve body bolt torque.9. Inspect servo bore, piston, seals, pin, spring, and retainers; repair or replace as

necessary and adjust bands.10. Inspect accumulator bore, piston, seals, spring, and retainers; repair or replace as

necessary.11. Inspect parking gear, inspect and replace parking pawl, shaft, spring, and retainer.12. Inspect, test, adjust, repair, or replace electrical/electronic components and circuits

including computers, solenoids, sensors, relays, terminals, connectors, switches, andharnesses.

13. Inspect, replace, and align power train mounts.D. Off-Vehicle Transmission/ Transaxle Repair (11 questions)1. Removal , Disassembly, and Assembly (3 questions)

1. Remove and replace transmission/transaxle; inspect engine core plugs, rearcrankshaft seal, transmission dowel pins, and dowel pin holes.

2. Disassemble, clean, and inspect transmission case and sub-assemblies.3. Assemble after repair.4. Inspect converter flex (drive) plate, converter attaching bolts, converter pilot,

converter pump drive surfaces, and crankshaft bore.2. Gear Train, Shafts, Bushings, Oil Pump, and Case (4 questions)

1. Inspect, measure, and replace oil pump components.2. Check bearing preload; determine needed service.3. Check end play; inspect, measure, and replace thrust washers and bearings as

needed.4. Inspect and replace shafts.5. Inspect oil delivery circuit, including seal rings, ring grooves, sealing surface areas,

feed pipes, orifices, and encapsulated check valves (balls).6. Inspect and replace bushings.7. Inspect and measure planetary gear assembly; replace parts as necessary.8. Inspect, repair, and replace case bores, passages, bushings, vents, mating surfaces,

thread condition, and dowel pins.

9. Inspect, repair or replace transaxle drive chains, sprockets, gears, bearings, andbushings.10. Inspect, measure, repair, adjust or replace transaxle final drive components.3. Friction and Reaction Units (4 questions)

1. Inspect hydraulic clutch pack assembly; replace parts as necessary.2. Measure and adjust clutch pack clearance.3. Air test the operation of clutch and servo assemblies.4. Inspect one-way clutch assemblies; replace parts as necessary.5. Inspect and replace bands and drums (housings/cylinders).


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SAMPLE QUESTIONSAUTOMATIC TRANSMISSION /TRANSAXLE (TEST A2)

1. An automatic transmission does not hold in PARK. Technician A says thatmisadjusted shift linkage could be the cause. Technician B says that a rollerclutch installed backwards could be the cause. Who is right?



Technician As statement is correct. Misadjusted shift linkage could deep theparking pawl from engaging the parking gear. Since the park gear is splined tothe mainshaft, and is the only direct mechanical connection to the vehicleswheels, the vehicle could roll.

Technician Bs statement is incorrect. The roller clutch serves the same purposeas the low/reverse band. It is a reaction member which comes into play, wheneverthe DRIVE position is selected, by holding the low/reverse drum against CCWrotation in all forward gears. It is not attached to the mainshaft.

2. A vehicle with an automatic transaxle, and a properly tuned engine, acceleratespoorly from a stop. Acceleration is normal above 35 mph. Which of these couldbe the cause?

(A) A worn front pump (C) A bad governor valve(B) A bad torque converter (D) A low fluid level

3. When the engine is idling, transmission line pressures are low in all selector leverpositions. Which of these is the most likely cause?

(A) Vacuum diaphragm unit (C) Connecting vacuum tubes(B) Throttle (modulator) valve (D) Transmission pump

4. An automatic transaxle does not shift properly. Which of these should thetechnician do first?

(A) Do a pressure test (C) Check the fluid level(B) Adjust the band(s) (D) Check engine vacuum

Questions:


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5. With the transmission pan removed, the best way to pin-point an oil pressure leak is to:

(A) check the filter pick-up tube seal.(B) check the line pressure.(C) remove and check the valve body.(D) perform an air pressure test.

6. The tool in the setup shown above is being used to remove the:(A) pump bushing. (C) stator support.(B) pump seal. (D) stator seal.

7. When installing a valve body, a technician strips the threads in the transmissioncase. To fix this condition the technician should:

(A) drill and retap the hole for a larger cap screw.(B) use a longer cap screw.(C) use a thread repair kit.(D) use an epoxy repair kit.


It has the word EXCEPT. For this question, look for the choice that could NOTcause the described situation. Read the entire question carefully before choosingyour answer.

8. Too much automatic transmission shaft end play could be caused by any of theseEXCEPT a worn:

(A) clutch.(B) selective washer.(C) transmission case.(D) planetary carrier.


Answer Key:1. A 2. B 3. D 4. C 5. D 6. A 7. C 8. A

TOOL


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TEST SPECIFICATIONSMANUAL DRIVE TRAIN AND AXLES (TEST A3)


A. Clutch Diagnosis and Repair 6 15%B. Transmission Diagnosis and Repair 6 15%C. Transaxle Diagnosis and Repair 8 20%D. Drive (Half) Shaft and Universal

Joint/Constant Velocity (CV) JointDiagnosis and Repair (Front and RearWheel Drive) 6 15%

E. Rear Axle Diagnosis and Repair 7 17%1. Ring and Pinion Gears (3)2. Differential Case Assembly (2)3. Limited Slip Differential (1)4. Axle Shafts (1)

F. Four-Wheel Drive Component Diagnosisand Repair 7 17%

Total 40 1 100%



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TASK LISTMANUAL DRIVE TRAIN AND AXLES (TEST A3)


A. Clutch Diagnosis and Repair (6 questions)1. Diagnose clutch noise, binding, slippage, pulsation, chatter, pedal feel/effort, and

release problems; determine needed repairs.2. Inspect, adjust, and replace clutch pedal linkage, cables and automatic adjuster

mechanisms, brackets, bushings, pivots, and springs.3. Inspect, adjust, replace, and bleed hydraulic clutch slave and master cylinders, lines,

and hoses.4. Inspect, adjust, and replace release (throw-out) bearing, lever, and pivot.5. Inspect and replace clutch disc and pressure plate assembly.6. Inspect and replace pilot bearing.7. Inspect and measure flywheel and ring gear; repair or replace as necessary.8. Inspect engine block, clutch (bell) housing, and transmission case mating surfaces;

determine needed repairs.9. Measure flywheel-to-block runout and crankshaft end play; determine needed repairs.

10. Measure clutch (bell) housing bore-to-crankshaft runout and face squareness;determine needed repairs.

11. Inspect, replace, and align powertrain mounts.B. Transmission Diagnosis and Repair (6 questions)

1. Diagnose transmission noise, hard shifting, jumping out of gear, and fluid leakageproblems; determine needed repairs.

2. Inspect, adjust, and replace transmission external shifter assembly, shift linkages,brackets, bushings/grommets, pivots, and levers.

3. Inspect and replace transmission gaskets, sealants, seals, and fasteners; inspectsealing surfaces.

4. Remove and replace transmission; inspect transmission mounts.5. Disassemble and clean transmission components; reassemble transmission.6. Inspect, repair, and/or replace transmission shift cover and internal shift forks,

bushings, levers, shafts, sleeves, detent mechanisms, interlocks, and springs.7. Inspect and replace input (clutch) shaft, bearings, and retainers.8. Inspect and replace main shaft, gears, thrust washers, bearings, and retainers/snap

rings.9. Inspect and replace synchronizer hub, sleeve, keys (inserts), springs, and blocking

(synchronizing) rings; measure blocking ring clearance.10. Inspect and replace counter (cluster) gear, shaft, bearings, thrust washers, and

retainers/snap rings.


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11. Inspect and replace reverse idler gear, shaft, bearings, thrust washers, and retainers/ snap rings.

12. Measure and adjust shaft, gear, and synchronizer end play.13. Measure and adjust bearing preload.14. Inspect, repair, and replace extension housing and transmission case mating

surfaces, bores, bushings, and vents.15. Inspect and replace speedometer drive gear, driven gear, and retainers.16. Inspect, test, and replace transmission sensors and switches.17. Inspect lubrication devices; check fluid level, and refill with proper fluid.

C. Transaxle Diagnosis and Repair (8 questions)1. Diagnose transaxle noise, hard shifting, jumping out of gear, and fluid leakage

problems; determine needed repairs.2. Inspect, adjust, and replace transaxle external shift assemblies, linkages, brackets,

bushings/grommets, cables, pivots, and levers.3. Inspect and replace transaxle gaskets, sealants, seals, and fasteners; inspect sealing

surfaces.4. Remove and replace transaxle; inspect, replace, and align transaxle mounts.5. Disassemble and clean transaxle components; reassemble transaxle.6. Inspect, repair, and/or replace transaxle shift cover and internal shift forks, levers,

bushings, shafts, sleeves, detent mechanisms, interlocks, and springs.7. Inspect and replace input shaft, bearings, and retainers.8. Inspect and replace output shaft, gears, thrust washers, bearings, and retainers/snap rings.9. Inspect and replace synchronizer hub, sleeve, keys (inserts), springs, and blocking

(synchronizing) rings; measure blocking ring clearance.10. Inspect and replace reverse idler gear, shaft, bearings, thrust washers, and retainers/

snap rings.11. Inspect, repair, and replace transaxle case mating surfaces, bores, bushings, and

vents.12. Inspect and replace speedometer drive gear, driven gear, and retainers.13. Inspect, test, and replace transaxle sensors and switches.14. Diagnose differential assembly noise and vibration problems; determine needed repairs.15. Remove and replace differential assembly.16. Inspect, measure, adjust and replace differential pinion gears (spiders), shaft, side

gears, thrust washers, and case.17. Inspect and replace differential side bearings.18. Measure shaft end play/preload (shim/spacer selection procedure).19. Inspect lubrication devices; check fluid level and refill with proper fluid.

D. Drive (Half) Shaft and Universal Joint /Constant Velocity (CV) Joint Diagnosis andRepair (Front and Rear Wheel Drive) (6 questions)

1. Diagnose shaft and universal/CV joint noise and vibration problems; determineneeded repairs.

2. Inspect, service, and replace shafts, yokes, boots, and universal/CV joints.3. Inspect, service, and replace shaft center support bearings.4. Check and correct propeller shaft balance.5. Measure shaft runout.6. Measure and adjust shaft angles.


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E. Rear Wheel Drive Axle Diagnosis and Repair (7 questions)1. Ring and Pinion Gears (3 questions)

1. Diagnose noise, vibration, and fluid leakage problems; determine needed repairs.2. Inspect and replace companion flange and pinion seal; measure companion flange

runout.3. Measure ring gear runout; determine needed repairs.4. Inspect and replace ring and pinion gear set, collapsible spacers, sleeves (shims),

and bearings.5. Measure and adjust drive pinion depth.6. Measure and adjust drive pinion bearing preload (collapsible spacer or shim type).7. Measure and adjust differential (side) bearing preload, and ring and pinion backlash

(threaded cup or shim type).8. Perform ring and pinion tooth contact pattern checks; determine needed adjustments.

2. Differential Case Assembly (2 questions)1. Diagnose differential assembly noise and vibration problems; determine needed repairs.2. Remove and replace differential assembly.3. Inspect, measure, adjust and replace differential pinion gears (spiders), shaft, side

gears, thrust washers, and case.4. Inspect and replace differential side bearings.5. Measure differential case runout; determine needed repairs.

3. Limi ted Slip Differential (1 question)1. Diagnose limited slip differential noise, slippage, and chatter problems; determine

needed repairs.2. Inspect, flush, and refill with correct lubricant.3. Inspect, adjust, and replace clutch (cone/plate) pack.

4. Axle Shafts (1 question)1. Diagnose rear axle shaft noise, vibration, and fluid leakage problems; determine

needed repairs.

2. Inspect and replace rear axle shaft wheel studs.3. Remove, inspect, and replace rear axle shafts, seals, bearings, and retainers.4. Measure rear axle flange runout and shaft end play; determine needed repairs.

F. Four-Wheel Drive Component Diagnosis and Repair (7 questions)1. Diagnose four-wheel drive assembly noise, vibration, shifting, and steering

problems; determine needed repairs.2. Inspect, adjust, and repair transfer case manual shifting mechanisms, bushings,

mounts, levers, and brackets.3. Remove and replace transfer case.

4. Disassemble and clean transfer case and components; reassemble transfer case.5. Inspect and service transfer case and internal components; check lube level.6. Inspect, service, and replace front-drive (propeller) shafts and universal/CV joints.7. Inspect, service, and replace front-drive axle knuckles and driving shafts.8. Inspect, service, and replace front wheel bearings and locking hubs.9. Check transfer case and front axle seals and remote vents.

10. Diagnose, test, adjust, and replace electrical/electronic components of 4WD systems.


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SAMPLE QUESTIONSMANUAL DRIVE TRAIN AND AXLES (TEST A3)

1. A manual transmission slips out of high gear. Which of these could be the cause?

(A) Worn blocking rings(B) Too much main shaft end play(C) Broken synchronizer keys(D) Worn shifter interlocks


Option (B) is correct. When the main (output) shaft has excessive end play, thereis a tendency for it to move forward and backward. Over time, and with enoughend play, the small engaged teeth on the direct drive gear will gradually work theirway out of the synchronizer hub. Since the hub is splined to the main shaft, the

power connection is lost when this occurs.Option (A) is wrong. The function of the blocking rings is to match the speeds of the mainshaft and the gear being shifted. Once engagement is complete, there isno drive or thrust against the blocking rings.

Option (C) is wrong. Like the blocking rings, the synchronizer keys are activeonly during the actual gear shift when they are used to hold the blocking rings andallow them just enough rotation to make a smooth engagement.

Option (D) is wrong. During each gear shift, the shifter interlocks are reposi-tioned so that it is impossible to force the transmission into two gears at once. Theinterlocks do not hold the transmission in gear.

2. In a vehicle with a single-plate clutch, loss of free pedal can be caused by a:

(A) worn release bearing.(B) broken clutch linkage.(C) worn clutch disc facing.

(D) weak pressure plate springs.

3. A four-speed fully synchronized transmission has a clunking or knocking noisein first and reverse only. Technician A says that a broken tooth on the clutch(input) gear could be the cause. Technician B says that a broken tooth on thecounter (cluster) gear could be the cause. Who is right?


Questions:


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4. A manual transaxle makes a clunking noise on acceleration and on deceleration.Technician A says that a loose differential case pinion shaft could be the cause.Technician B says that worn CV joints could be the cause. Who is right?


5. Technician A says that the set-up shown above can be used to check pinion-to-ring gear preload. Technician B says that the set-up can be used to check pinionflange nut torque. Who is right?


6. The set-up shown above is being used to check:

(A) ring gear runout. (C) side gear runout.(B) ring gear backlash. (D) differential case-to-ring gear clearance.


PINION YOKEINCH POUND

TORQUE WRENCH


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7. A four-wheel drive vehicle vibrates while the front axle is engaged. TechnicianA says that a bad front axle shaft U-joint could be the cause. Technician B saysthat different front and rear tire diameters could be the cause. Who is right?



It has the word EXCEPT. For this question, look for the choice that could NOT

cause the described situation. Read the entire question carefully before choosingyour answer.

8. The clutch does not release fully when the pedal is pushed to the floor. Any of these could be the cause EXCEPT:

(A) weak pressure plate springs.(B) too much free pedal travel.(C) a warped clutch disc.(D) a seized pilot bearing.

Answer Key:1. B 2. C 3. B 4. C 5. D 6. A 7. C 8. A


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TEST SPECIFICATIONSSUSPENSION AND STEERING (TEST A4)


A. Steering Systems Diagnosis and Repair 10 25%1. Steering Columns and

Manual Steering Gears (3)2. Power-Assisted Steering Units (4)3. Steering Linkage (3)

B. Suspension Systems Diagnosisand Repair 13 33%1. Front Suspensions (6)2. Rear Suspensions (5)3. Miscellaneous Service (2)

C. Wheel Alignment Diagnosis,Adjustment, and Repair 12 30%

D. Wheel and Tire Diagnosisand Repair 5 12%

Total 40 1 100%



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TASK LISTSUSPENSION AND STEERING (TEST A4)


A. Steering Systems Diagnosis and Repair (10 questions)1. Steering Columns and Manual Steering Gears (3 questions)

1. Diagnose steering column noises and steering effort concerns (including manual andelectronic tilt and telescoping mechanisms); determine needed repairs.

2. Diagnose manual steering gear (non-rack and pinion type) noises, binding, vibration,freeplay, steering effort, and lubricant leakage concerns; determine needed repairs.

3. Diagnose manual rack and pinion steering gear noises, binding, vibration, freeplay,steering effort, and lubricant leakage concerns; determine needed repairs.

4. Inspect and replace steering column, steering shaft U-joint(s), flexible coupling(s),collapsible columns, steering wheels (includes steering wheels with air bags and/orother steering wheel mounted controls and components).

5. Remove and replace manual steering gear (non-rack and pinion type) (includesvehicles equipped with air bags and/or other steering wheel mounted controls andcomponents).

6. Adjust manual steering gear (non-rack and pinion type) worm bearing preload andsector lash.

7. Remove and replace manual rack and pinion steering gear (includes vehiclesequipped with air bags and/or other steering wheel mounted controls and compo-nents).

8. Adjust manual rack and pinion steering gear.9. Inspect and replace manual rack and pinion steering gear inner tie rod ends (sockets)

and bellows boots.10. Inspect and replace manual rack and pinion steering gear mounting bushings and

brackets.2. Power-Assisted Steering Units (4 questions)

1. Diagnose power steering gear (non-rack and pinion type) noises, binding, vibration,freeplay, steering effort, steering pull (lead), and fluid leakage concerns; determineneeded repairs.

2. Diagnose power rack and pinion steering gear noises, binding, vibration, freeplay,steering effort, steering pull (lead), and fluid leakage concerns; determine neededrepairs.

3. Inspect power steering fluid level and condition; adjust level in accordance withvehicle manufacturers recommendations.


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4. Inspect, adjust, align, and replace power steering pump belt(s) and tensioners.5. Diagnose power steering pump noises, vibration, and fluid leakage; determine

needed repairs.6. Remove and replace power steering pump; inspect pump mounting and attaching

brackets.7. Inspect and replace power steering pump seals, gaskets, reservoir and valves.8. Inspect and replace power steering pump pulley.9. Perform power steering system pressure and flow tests; determine needed repairs.

10. Inspect and replace power steering hoses, fittings, O-rings and coolers.11. Remove and replace power steering gear (non-rack and pinion type) (includes

vehicles equipped with air bags and/or other steering wheel mounted controls andcomponents).

12. Remove and replace power rack and pinion steering gear; inspect and replacemounting bushings and brackets (includes vehicles equipped with air bags and/orother steering wheel mounted controls and components).

13. Adjust power steering gear (non-rack and pinion type) worm bearing preload andsector lash.

14. Inspect and replace power steering gear (non-rack and pinion type) seals andgaskets.

15. Adjust power rack and pinion steering gear.16. Inspect and replace power rack and pinion steering gear inner tie rod ends (sockets),

and bellows boots.17. Flush, fill, and bleed power steering system.18. Diagnose, inspect, repair or replace components of variable-assist steering systems.19. Diagnose, inspect, repair or replace components of power steering idle speed

compensation systems.3. Steering Linkage (3 questions)

1. Inspect and adjust (where applicable) front and rear steering linkage geometry(including parallelism and vehicle ride height).

2. Inspect and replace pitman arm.3. Inspect and replace center link (relay rod/drag link/intermediate rod).4. Inspect, adjust (where applicable), and replace idler arm and mountings.5. Inspect, replace, and adjust tie rods, tie rod sleeves, clamps, and tie rod ends

(sockets).6. Inspect and replace steering linkage damper.

B. Suspension Systems Diagnosis and Repair (13 questions)1. Front Suspensions (6 questions)

1. Diagnose front suspension system noises, body sway/roll, and ride height concerns;determine needed repairs.2. Inspect and replace upper and lower control arms, bushings, shafts, rebound and

jounce bumpers.3. Inspect, adjust, and replace strut rods/radius arms (compression/tension), and

bushings.4. Inspect and replace upper and lower ball joints (with or without wear indicators).5. Inspect and replace kingpins, bearings, and bushings.6. Inspect and replace steering knuckle/spindle assemblies and steering arms.


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7. Inspect and replace front suspension system coil springs and spring insulators(silencers).

8. Inspect and replace front suspension system leaf spring(s), leaf spring insulators(silencers), shackles, brackets, bushings, and mounts.

9. Inspect, replace, and adjust front suspension system torsion bars and mounts.10. Inspect and replace stabilizer bar (sway bar) bushings, brackets, and links.11. Inspect and replace strut cartridge or assembly.12. Inspect and replace strut bearing and mount.

2. Rear Suspensions (5 questions)1. Diagnose rear suspension system noises, body sway/roll, and ride height concerns;

determine needed repairs.2. Inspect and replace rear suspension system coil springs and spring insulators

(silencers).3. Inspect and replace rear suspension system lateral links/arms (track bars), control

(trailing) arms, stabilizer bars (sway bars), bushings, and mounts.4. Inspect and replace rear suspension system leaf spring(s), leaf spring insulators

(silencers), shackles, brackets, bushings, and mounts.5. Inspect and replace rear strut cartridge or assembly, and upper mount assembly.6. Inspect non-independent rear axle assembly for bending, warpage, and misalign-

ment.7. Inspect and replace rear ball joints and tie rod/toe link assemblies.8. Inspect and replace knuckle/spindle assembly.

3. Miscellaneous Service (2 questions)1. Inspect and replace shock absorbers, mounts, and bushings.2. Inspect and replace air shock absorbers, lines, and fittings.3. Diagnose and service front and/or rear wheel bearings.4. Diagnose, inspect, adjust, repair or replace components of electronically controlled

suspension systems (including primary and supplemental air suspension and ridecontrol systems).

5. Inspect and repair front and/or rear cradle (crossmember/subframe) mountings,bushings, brackets, and bolts.

C. Wheel Alignment Diagnosis, Adjustm ent, and Repair (12 questions)1. Diagnose vehicle wander, drift, pull, hard steering, bump steer (toe curve), memory

steer, torque steer, and steering return concerns; determine needed repairs.2. Measure vehicle ride height; determine needed repairs.3. Check and adjust front and rear wheel camber on suspension systems with a camber

adjustment.

4. Check front and rear wheel camber on non-adjustable suspension systems; deter-mine needed repairs.5. Check and adjust caster on suspension systems with a caster adjustment.6. Check caster on non-adjustable suspension systems; determine needed repairs.7. Check and adjust front wheel toe.8. Center steering wheel.9. Check toe-out-on-turns (turning radius/angle); determine needed repairs.

10. Check SAI/KPI (steering axis inclination/king pin inclination); determine neededrepairs.


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SAMPLE QUESTIONSSUSPENSION AND STEERING (TEST A4)

1. The front end of a vehicle vibrates up and down while traveling at most roadspeeds. Technician A says that too much radial runout of the front tires could bethe cause. Technician B says that static out-of-balance of the front tires could be

the cause. Who is right?(A) A only (C) Both A and B(B) B only (D) Neither A nor B


Technician As diagnosis is correct. Radial runout, as shown above, is a conditionwhere the wheel and tire assembly is out-of-round. As the tire rotates, the spindlewill have to move up and down in relationship to the road surface. This movement

would produce a vibration which could be noticed by the driver.

Technician Bs diagnosis is also correct. Static imbalance, as shown above, is acondition where there is an unequal distribution of weight around the axis of thetire. As the tire rotates, centrifugal force will act on the heavy spot causing the tireto tramp or hop. This tramping action would produce a vibration which couldbe noticed by the driver. Because both Technician A and Technician B arecorrect, the answer to this question is (C).

RADIALRUNOUT

HEAVYSPOT

Questions:


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2. A vehicle wanders while being driven on level roads. Technician A says that toomuch negative camber could be the cause. Technician B says that too muchpositive caster could be the cause. Who is right?


3. The alignment settings shown above would result in which of these conditions?

(A) Left tire wear on inside; vehicle does not pull to either side(B) Right tire wear on inside; vehicle pulls to left(C) Right tire wear on outside; vehicle pulls to left(D) Right tire wear on outside; left tire wear on inside; vehicle pulls to left

4. A vehicle with manual rack and pinion steering has a shimmy. Technician A saysthat worn rack-to-frame mounting bushings could be the cause. Technician Bsays that loose inner or outer tie rod ends (sockets) could be the cause. Who isright?

(A) A only (C) Both A and B

(B) B only (D) Neither A nor B

5. During a wheel alignment, a technician finds the toe-out-on-turns (turningradius) to be incorrect. Which of these could be the cause?

(A) Bent pitman arm(B) Bent tie rod(C) Bent idler arm(D) Bent steering arm

6. A vehicle pulls to the right during braking. Technician A says that a worn strutrod bushing could be the cause. Technician B says that a bent right wheel couldbe the cause. Who is right?


READINGS SPECS

Left Right Left or Right

+ 3/4 or - 1 1/2 or 0 to + 1/2 or

Camber + 45 min. - 1

30 min. 0 to + 30 min.Caster 0 0 0 to + 1

1/16" or 1/16" to 3/16" orToe-in .16mm .16mm to .48mm



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7. The ball joints on the MacPherson strut suspension system shown above arebeing replaced. Technician A says that a coil spring compressor should beinstalled before separating the control arm and spindle. Technician B says that thewheel alignment should be checked after the ball joints have been replaced. Who

is right?(A) A only (C) Both A and B(B) B only (D) Neither A nor B

8. A pressure test is being performed on a vehicle with power steering. The pressurereadings taken when the wheels are at the right and left stops are below specs. Thereadings are normal when the tester shutoff valve is closed. Technician A says

that these readings could be caused by a bad steering gear. Technician B says thatthese readings could be caused by a bad pump. Who is right?



COIL SPRING

STRUTROD

SHOCK

STRUTSPINDLE

STABILIZERBAR

CONTROL ARM

BALL JOINT


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9. The suspension shown above is being checked for ball joint wear. Technician Asays that the check can be made with the front end jacked up at X. TechnicianB says that the check can be made with the front end jacked up at Y. Who isright?



It has the word EXCEPT. For this question, look for the choice that could NOTcause the described situation. Read the entire question carefully before choosingyour answer.

10. All of these could cause tire wear if not within manufacturers specs EXCEPT:

(A) caster. (C) toe-in.(B) wheel balance. (D) camber.


Answer Key:1. C 2. D 3. B 4. C 5. D 6. A 7. B 8. A 9. B 10. A

X Y


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TEST SPECIFICATIONSBRAKES (TEST A5)


A. Hydraulic System Diagnosis and Repair 14 25%1. Master Cylinders (non-ABS) (3)2. Fluids, Lines, and Hoses (3)3. Valves and Switches (non-ABS) (4)4. Bleeding, Flushing, and Leak

Testing (non-ABS) (4)B. Drum Brake Diagnosis and Repair 6 11%C. Disc Brake Diagnosis and Repair 13 24%D. Power Assist Units Diagnosis and Repair 4 7%E. Miscellaneous Diagnosis and Repair 7 13%F. Antilock Brake System Diagnosis and Repair 11 20%

Total 55 1 100%

1Note: There could be up to ten additional questions that are included for statisticalresearch purposes only. Your answers to these questions will not affect your testscore, but since you do not know which ones they are, you should answer allquestions in the test. The five-year Recertification Test will cover the same contentareas as those listed above. However, the number of questions in each content areaof the Recertification Test will be reduced by about one-half.


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TASK LISTBRAKES (TEST A5)

A. Hydraulic System Diagnosis and Repair (14 questions)1. Master Cylinder (Non-ABS) (3 questions)

1. Diagnose poor stopping or dragging caused by problems in the master cylinder;determine needed repairs.

2. Diagnose poor stopping, dragging, high or low pedal, or hard pedal caused byproblems in the step bore master cylinder and internal valves (e.g. volume controldevices, quick take-up valve, fast-fill valve, pressure regulating valve); determineneeded repairs.

3. Measure and adjust master cylinder pushrod length.4. Check master cylinder for defects by depressing brake pedal; determine needed repairs.5. Diagnose the cause of master cylinder external fluid leakage.6. Remove master cylinder from vehicle; install master cylinder; test operation of the

hydraulic system.7. Bench bleed (check for function and remove air) all non-ABS master cylinders.

2. Fluids, Lines, and Hoses (3 questions)1. Diagnose poor stopping, pulling, or dragging caused by problems in the brake fluid,

lines, and hoses; determine needed repairs.2. Inspect brake lines and fittings for leaks, dents, kinks, rust, cracks, or wear; tighten

loose fittings and supports.3. Inspect flexible brake hoses for leaks, kinks, cracks, bulging, or wear; tighten loose

fittings and supports.4. Fabricate and/or replace brake lines (double flare and ISO types), hoses, fittings, and

supports.5. Select, handle, store, and install proper brake fluids (including silicone fluids).6. Inspect brake lines and hoses for proper routing.

3. Valves and Swi tches (Non-ABS) (4 questions)1. Diagnose poor stopping, pulling, or dragging caused by problems in the hydraulic

system valve(s); determine needed repairs.2. Inspect, test, and replace metering, proportioning, pressure differential, and

combination valves.3. Inspect, test, replace, and adjust load or height sensing-type proportioning valve(s).4. Inspect, test, and replace brake warning light, switch, and wiring.



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4. Bleeding, Flushing, and Leak Testing (Non-ABS) (4 questions)1. Bleed (manual, pressure, vacuum, or surge method) and/or flush hydraulic system.2. Pressure test brake hydraulic system.

B. Drum Brake Diagnosis and Repair (6 questions)1. Diagnose poor stopping, pulling, or dragging caused by drum brake hydraulic

problems; determine needed repairs.2. Diagnose poor stopping, noise, pulling, grabbing, dragging, or pedal pulsation

caused by drum brake mechanical problems; determine needed repairs.3. Remove, clean, inspect, and measure brake drums; follow manufacturers recom-

mendations in determining need to machine or replace.4. Machine drums according to manufacturers procedures and specifications.5. Using proper safety procedures, remove, clean, and inspect brake shoes/linings,

springs, pins, self-adjusters, levers, clips, brake backing (support) plates and otherrelated brake hardware; determine needed repairs.

6. Lubricate brake shoe support pads on backing (support) plate, self- adjustermechanisms, and other brake hardware.

7. Install brake shoes and related hardware.8. Pre-adjust brake shoes and parking brake before installing brake drums or drum/hub

assemblies and wheel bearings.9. Reinstall wheel, torque lug nuts, and make final checks and adjustments.

C. Disc Brake Diagnosis and Repair (13 questions)1. Diagnose poor stopping, pulling, or dragging caused by disc brake hydraulic

problems; determine needed repairs.2. Diagnose poor stopping, noise, pulling, grabbing, dragging, pedal pulsation or pedal

travel caused by disc brake mechanical problems; determine needed repairs.3. Retract integral parking brake caliper piston(s) according to manufacturers

recommendations.4. Remove caliper assembly from mountings; clean and inspect for leaks and damage

to caliper housing.5. Clean, inspect, and measure caliper mountings and slides for wear and damage.6. Remove, clean, and inspect pads and retaining hardware; determine needed repairs,

adjustments, and replacements.7. Disassemble and clean caliper assembly; inspect parts for wear, rust, scoring, and

damage; replace all seals, boots, and any damaged or worn parts.8. Reassemble caliper.9. Clean, inspect, and measure rotor with a dial indicator and a micrometer; follow

manufacturers recommendations in determining need to machine or replace.

10. Remove and replace rotor.11. Machine rotor, using on-car or off-car method, according to manufacturersprocedures and specifications.

12. Install pads, calipers, and related attaching hardware; bleed system.13. Adjust calipers with integrated parking brakes according to manufacturers recom-

mendations.14. Fill master cylinder to proper level with recommended fluid; inspect caliper for

leaks.15. Reinstall wheel, torque lug nuts, and make final checks and adjustments.


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8. The set-up shown above is used to check:

(A) rotor parallelism. (C) rotor lateral runout (wobble).(B) wheel bearing adjustment. (D) rotor face wear.

9. The drag on a vehicles drum brakes increases after each application until theylockup. Bleeding the system restores normal operation for a short time; then dragincreases until the brakes lockup again. Which of these could be the cause?

(A) A blocked compensating port (C) Wrong brake shoe adjustment(B) A blocked breather port (D) Weak brake shoe return springs

10. With the brakes applied, the pedal moves down slightly when the engine is startedon a vehicle with power brakes. Technician A says that the cause could be aleaking power brake booster diaphragm. Technician B says that the cause couldbe a stuck closed check valve on the power brake booster manifold. Who is right?



Answer Key:1. C 2. A 3. C 4. D 5. C 6. D 7. D 8. C 9. A 10. D


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TEST SPECIFICATIONSELECTRICAL /ELECTRONIC SYSTEMS (TEST A6)


A. General Electrical/Electronic System Diagnosis 13 26%B. Battery Diagnosis and Service 4 8%C. Starting System Diagnosis and Repair 5 10%D. Charging System Diagnosis and Repair 5 10%E. Lighting Systems Diagnosis and Repair 6 12%

1. Headlights, Parking Lights,Taillights, Dash Lights, andCourtesy Lights (3)

2. Stoplights, Turn Signals, HazardLights, and Back-up Lights (3)

F. Gauges, Warning Devices, and DriverInformation Systems Diagnosis and Repair 6 12%

G.Horn and Wiper/Washer Diagnosis and Repair 3 6%H. Accessories Diagnosis and Repair 8 16%

1. Body (4)2. Miscellaneous (4)

Total 50 1 100%



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TASK LISTELECTRICAL /ELECTRONIC SYSTEMS (TEST A6)


A. General Electr ical /Electr onic System Diagnosis (13 questions)1. Check electrical circuits with a test light; determine needed repairs.2. Check voltages and voltage drops in electrical/electronic circuits with a voltmeter;

interpret readings and determine needed repairs.3. Check current flow in electrical/electronic circuits and components with an

ammeter; interpret readings and determine needed repairs.4. Check continuity and resistances in electrical/electronic circuits and components

with an ohmmeter; interpret readings and determine needed repairs.5. Check electronic circuit waveforms using an oscilloscope; interpret readings and

determine needed repairs.6. Use scan-tool data to diagnose electronic systems; interpret readings and determine

needed repairs.7. Check electrical/electronic circuits with jumper wires; determine needed repairs.8. Find shorts, grounds, opens, and resistance problems in electrical/ electronic

circuits; determine needed repairs.9. Measure and diagnose the cause(s) of abnormal key-off battery drain (parasitic

draw); determine needed repairs.10. Inspect, test, and replace fusible links, circuit breakers, fuses, diodes, and other

current limiting devices.11. Read and interpret electrical schematic diagrams and symbols.

B. Battery Diagnosis and Service (4 questions)1. Perform battery state-of-charge test; determine needed service.2. Perform battery capacity (load, high-rate discharge) test; determine needed service.3. Maintain or restore electronic memory functions.4. Inspect, clean, fill, or replace battery.5. Perform slow/fast battery charge in accordance with manufacturers recommenda-

tions.6. Inspect, clean, and repair or replace battery cables, connectors, clamps and

holddowns.7. Jump start a vehicle with jumper cables and a booster battery or auxiliary power

supply.C. Starting System Diagnosis and Repair (5 questions)

1. Perform starter current draw test; determine needed repairs.


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2. Perform starter circuit voltage drop tests; determine needed repairs.3. Inspect, test, and repair or replace switches, connectors, and wires of starter control

circuits.4. Inspect, test, and replace starter relays and solenoids.5. Remove and replace starter.6. Differentiate between electrical and engine mechanical problems that cause a slow

crank or no crank condition.D. Charging System Diagnosis and Repair (5 questions) Note: In 1996, SAE J1930 terminology was adopted to standardize component

identification. This standard adopted the name generator to refer to the componentcommonly known as an alternator. Both terms are used interchangeably in theASE tests.

1. Diagnose charging system problems that cause an undercharge, a no-charge, or anovercharge condition.

2. Inspect, adjust, and replace generator (alternator) drive belts, pulleys, andtensioners.

3. Perform charging system output test; determine needed repairs.4. Perform generator (alternator) output test; determine needed repairs.5. Inspect, and test voltage regulator/field control circuit; determine needed repairs.6. Perform charging circuit voltage drop tests; determine needed repairs.7. Inspect, repair, or replace connectors and wires of charging circuits.8. Remove, inspect, and replace generator (alternator).

E. Lighting Systems Diagnosis and Repair (6 questions)1. Headlights, Parking Lights, Tail lights, Dash Lights, and Courtesy Lights(3 questions)

1. Diagnose the cause of brighter than normal, intermittent, dim, continuous or nooperation of headlights.

2. Inspect, test, and repair daytime running light systems.

3. Inspect, replace, and aim headlights/bulbs, and auxiliary lights (fog lights/drivinglights).4. Inspect, test, and repair or replace headlight and dimmer switches, relays, control

units, sensors, sockets, connectors, and wires of headlight circuits.4. Diagnose the cause of intermittent, slow, or no operation of retractable headlight

assembly.6. Inspect, test, and repair or replace motors, switches, relays, connectors, wires, and

controllers of retractable headlight assembly circuits.7. Diagnose the cause of brighter than normal, intermittent, dim, continuous or no

operation of parking lights, taillights, and/or auxiliary lights (fog lights/drivinglights).8. Inspect, test, and repair or replace switches, relays, bulbs, sockets, connectors,

wires, and controllers of parking light, taillight circuits, and auxiliary light circuits(fog lights/driving lights).

9. Diagnose the cause of intermittent, dim, no lights, continuing operation or nobrightness control of instrument lighting circuits.

10. Inspect, test, and repair or replace switches, relays, bulbs, sockets, connectors,wires, controllers, and printed circuit boards of instrument lighting circuits.


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11. Diagnose the cause of intermittent, dim, continuous or no operation of courtesylights (dome, map, vanity, cargo, trunk, and hood light).

12. Inspect, test, and repair or replace switches, relays, bulbs, sockets, connectors, wires, andcontrollers of courtesy light (dome, map, vanity, cargo, trunk, and hood light) circuits.

2. Stoplights, Turn Signals, Hazard Lights, and Back-up Lights (3 questions)1. Diagnose the cause of intermittent, dim, continuous or no operation of stoplights

(brake lights).2. Inspect, test, adjust, and repair or replace switch, bulbs, sockets, connectors, wires,

and controllers of stoplight (brake light) circuits.3. Diagnose the cause of no turn signal and/or hazard lights, or lights with no flash on

one or both sides.4. Inspect, test, and repair or replace switches, flasher units, bulbs, sockets, connectors,

wires, and controllers of turn signal and hazard light circuits.5. Diagnose the cause of intermittent, dim, improper, continuous or no operation of

back-up lights.6. Inspect, test, and repair or replace switch, bulbs, sockets, connectors, wires, and

controllers of back-up light circuits.7. Inspect, test, repair or replace trailer wiring harness and connector.

F. Gauges, Warning Devices, and Driver Inform ation Systems Diagnosis and Repair

(6 questions) Note: Diagnosing causes of abnormal charging system gauge readings or warning lightslimited to dash units and their electrical connections; other causes of abnormalcharging system indications are covered in category D.

1. Diagnose the cause of intermittent, high, low, or no gauge readings.2. Inspect, test, and repair or replace gauges, gauge sending units, connectors, wires,

controllers, and printed circuit boards of gauge circuits.3. Diagnose the cause(s) of intermittent, high, low, or no readings on electronic

instrument clusters.

4. Inspect, test, repair or replace sensors, sending units, connectors, wires, andcontrollers of electronic instrument circuits.5. Diagnose the cause of constant, intermittent, or no operation of warning light,

indicator lights, and other driver information systems.6. Inspect, test, and repair or replace bulbs, sockets, connectors, wires, electronic

components, and controllers of warning light, indicator light and driver informationsystem circuits.

7. Diagnose the cause of constant, intermittent, or no operation of audible warningdevices.

8. Inspect, test, and repair or replace switches, relays, sensors, timers, electroniccomponents, controllers, printed circuits, connectors, and wires of audible warningdevice circuits.

G. Horn and Wiper/Washer Diagnosis and Repair (3 questions)1. Diagnose the cause of constant, intermittent, or no operation of horn(s).2. Inspect, test, and repair or replace horn(s), horn relay, horn button (switch),

connectors, wires, and controllers of horn circuits.3. Diagnose the cause of wiper problems including constant operation, intermittent

operation, poor speed control, no parking, or no operation of wiper.


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4. Inspect, test, and replace intermittent (pulsing) wiper controls.5. Inspect, test, and replace wiper motor, resistors, switches, relays, controllers,

connections, and wires of wiper circuits.6. Diagnose the cause of constant, intermittent, or no operation of window washer.7. Inspect, test, and repair or replace washer motor, pump assembly, relays, switches,

connectors, and wires of washer circuits.H. Accessories Diagnosis and Repair (8 questions)1. Body (4 questions)

1. Diagnose the cause of slow, intermittent, or no operation of power windows.2. Inspect, test, and repair or replace regulators (linkages), switches, controllers, relays,

motors, connectors, and wires of power window circuits.3. Diagnose the cause of slow, intermittent, or no operation of power seat and driver

memory controls.4. Inspect, test, adjust, and repair or replace power seat gear box, cables, switches,

controllers, sensors, relays, solenoids, motors, connectors, and wires of power seatcircuits and driver memory controls.

5. Diagnose the cause of poor, intermittent, or no operation of rear window defogger.6. Inspect, test, and repair or replace switches, relays, timers, controllers, window grid,

connectors, and wires of rear window defogger circuits.7. Diagnose the cause of poor, intermittent, or no operation of electric door lock and

hatch/trunk lock.8. Inspect, test, and repair or replace switches, relays, controllers, actuators/solenoids,

connectors, and wires of electric door lock/hatch/trunk circuits.9. Diagnose the cause of poor, intermittent, or no operation of keyless and remote lock/

unlock devices.10. Inspect, test, and repair or replace components, connectors, controllers, and wires of

keyless and remote lock/unlock device circuits; reprogram system.11. Diagnose the cause of slow, intermittent, or no operation of electrical sunroof and

convertible/retractable top.12. Inspect, test, and repair or replace motors, switches, controllers, relays, connectors,and wires of electrically-operated sunroof and convertible/retractable top circuits.

13. Diagnose the cause of poor, intermittent, or no operation of electrically operated/ heated mirror.

14. Inspect, test and repair or replace motors, heated mirror grids, switches, controllers,relays, connectors, and wires of electrically operated/heated mirror circuits.

2. Miscellaneous (4 questions)1. Diagnose the cause of poor sound quality, noisy, erratic, intermittent, or no opera-

tion of the audio system, remove and reinstall audio system component (unit).2. Inspect, test, and repair or replace speakers, amplifiers, remote controls, antennas,leads, grounds, connectors, and wires of sound system circuits.

3. Inspect, test, and repair or replace switches, relays, motor, connectors, and wires of power antenna circuits.

4. Inspect, test, and replace noise suppression components.5. Inspect, test, and repair or replace case, fuse, connectors, relays, and wires of cigar

lighter/power outlet circuits.6. Inspect, test, and repair or replace clock, connectors, and wires of clock circuits.


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1. In the charging system shown above, the meter reading will show:

(A) charging output voltage.(B) indicator lamp applied voltage.(C) charging circuit voltage drop(D) ignition switch voltage drop.


When a voltmeter is connected between the power source and ground, the meterwill read the available voltage (voltage delivered by the power source). When avoltmeter is connected between a component and ground in an operating circuit,the meter will read the applied voltage (actual voltage at a given point in a circuit).A voltmeter connected between two points in an operating circuit will read thevoltage drop (voltage lost or used up in that portion of the circuit).

Option (A) is wrong. To read the output voltage the voltmeter should beconnected between the alternator battery terminal and ground.

Option (B) is wrong. To read the lamp applied voltage the voltmeter should be

connected between the indicator lamp terminal on the ignition switch side andground.

Option (C) is correct. The voltmeter in the setup shown above is connected at eachend of the power-feed (insulated) portion of the charging circuit. Therefore, itwill read the voltage drop caused by resistance of the wires and connections. Theresistance in the ground (non-insulated) portion of the circuit can be found byconnecting a voltmeter between the alternator ground and the negative (-) batterypost.

SAMPLE QUESTIONSELECTRICAL /ELECTRONIC SYSTEMS (TEST A6)

-BAT

SWITCH

+

VOLTMETERBAT

IGN.

RESISTOR

INDICATORLAMP

Questions:


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Option (D) is wrong. The switch voltage drop can be found by connecting avoltmeter between the ignition switch BAT. and IGN. terminals.

2. The oil pressure light stays on whenever the engine is running. The oil pressurehas been checked and meets specs. Technician A says that a ground in the circuitbetween the indicator light and the pressure switch could be the cause. TechnicianB says that an open in the pressure switch could be the cause. Who is right?


3. The bulb in the circuit shown above does not light. To find the actual voltage atthe bulb, the technician should touch the red (+) probe of the voltmeter

2000 auto prep guide

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