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CHF Chassis

This document provides an overview of chassis components, including suspension, steering, brakes, tires, and disc wheels, which are essential for vehicle operation. It details the functions and mechanisms of each component, such as how shock absorbers work, the types of brakes, and the importance of wheel alignment. Additionally, it covers the classification of shock absorbers and the operation of the steering system.
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0% found this document useful (0 votes)
11 views22 pages

CHF Chassis

This document provides an overview of chassis components, including suspension, steering, brakes, tires, and disc wheels, which are essential for vehicle operation. It details the functions and mechanisms of each component, such as how shock absorbers work, the types of brakes, and the importance of wheel alignment. Additionally, it covers the classification of shock absorbers and the operation of the steering system.
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 22

Frequent Service Job Course Chassis

Chassis
Chapter Outline

This chapter explains the mechanism and operation of chassis components.

• Chassis
• Suspension
• Steering
• Brake
• Tire
• Disc Wheel

ã2002 TOYOTA MOTOR CORPORATION. All right reserved.

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Frequent Service Job Course Chassis

Chassis

Chassis

Along with the exterior, interior, and engine, the chassis makes up
a vehicle. It manages the driving, turning, and stopping function.

1. Suspension
Physically supports the axles to ensure a better ride.

Front suspension
Rear suspension

2. Steering
Changes the direction of travel of the vehicle.

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Frequent Service Job Course Chassis

3. Brakes
Decelerate or stop the vehicle.

Foot brakes
Parking brakes

4. Tires & Disc Wheels


Support the vehicle through contact with the road surface.

(1/1)

Suspension

Suspension

The suspension system joins the wheels to the body or the frame
in order to support the vehicle physically.

• Improves the ride by dampening the impact that the tires


receive from the road surface.
• Ensures driving stability.

Front suspension
Rear suspension

Spring
Shock absorber
Stabilizer bar
Ball joint

(1/2)

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Frequent Service Job Course Chassis

Shock Absorbers

The shock absorbers restrain the movement of springs by the


resistance of the oil that flows through a path in the piston. They
also absorb the vibrations of the vehicle body, and give a good
ride.

Piston
Valve
Orifice
Spring
Shock absorber

REFERENCE:
Types of shock absorbers

Shock absorbers classified according to their operation,


construction, and by working medium.

Classification by operation
Classification by construction
Classification by working medium

(1/1)

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Frequent Service Job Course Chassis

Classification by operation
Single-action shock absorber
Type that damps the vibration of the spring when the shock
absorber extends, but doesn't damp it when it shrink.
Multi-action shock absorber
Type to damp the vibration of the spring when the shock absorber
both extends and shrinks.

Orifice
Valve
Fluid

Classification by construction
Mono-tube shock absorber
Type with only one cylinder (no reservoir)
Twin-tube shock absorber
Type with a cylinder consisting of a working chamber (inner
cylinder) and a reservoir chamber (outer cylinder).

Reservoir chamber
Working chamber
Air
Fluid
Valve

(1/1)

Classification by working medium


Hydraulic shock absorber
Type that uses the fluid (shock absorber fluid) as the medium to
operate the shock absorber.
Gas-filled shock absorber
Nitrogen gas is enclosed in the shock absorber. This pressures
the fluid and prevents the cavitation, in which the gas melted in
the fluid separates and bubbles are made.

Valve
Low-pressure gas
Fluid
Free piston
High-pressure gas

(1/1)

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Frequent Service Job Course Chassis

TEMS (Toyota Electronic Modulated Suspension)


The TEMS system uses an ECU (Electronic Control Unit) to
change the operating strength (damping force) of the shock
absorbers in accordance with the driving conditions.
While TEMS is operating, it secures a good ride or driving
stability, depending on the state of driving.
ECU controls the damping force of the shock absorber to keep the
vehicle flat.

ECU
Absorber control switch
Sensors
Absorber control actuator
Shock absorber
Starting-off
Strong damping force to stabilize the vehicle's posture.
Normal driving
Weak damping force to give a comfortable ride.
Turning
Strong damping force to stabilize the vehicle.
High-speed driving
Medium dampening force to give both a comfortable ride and
driving stability.
Braking
Strong dampening force to stabilize the vehicle.

(1/1)

Ball Joint

Ball joints bear vertical as well as horizontal loads, and also act as
pivots for the steering knuckles when the steering wheel is turned.

Stud
Boot
Seat
Housing
Rubber Cushion

(1/1)

Stabilizer Bar

When the vehicle turns a corner, it leans to the outside because of


the centrifugal force. The stabilizer bar controls it with the power of
the spring that twists, and keeps the tires close to the ground. It
also operates if the tires on one side runs onto a different on level.

When the vehicle leans and the tires sink to one side, the
stabilizer bar is twisted and operates as a spring, which lifts up the
tires) the body on the sinking side.
In case the tires on both sides sink equally, the stabilizer bar does
not operate as a spring because it is not twisted.

Stabilizer bar

(1/1)

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Frequent Service Job Course Chassis

Wheel Alignment

Vehicle must have proper straightline performance for stable


driving, and cornering performance for driving around curves.
Therefore, the wheels of a vehicle are mounted at specific angles
to the ground and specific suspensions for each purpose. This is
called wheel alignment.

Camber
Steering axis (Kingpin) inclination
Caster
Turning radius
Toe angle (Toe-in and Toe-out)

HINT:
Both front and rear wheels of vehicles are aligned, with the
exception of the wheels of rear rigid axle suspension FR vehicles.

Camber
This is the angle of the inclination of the wheel as viewed from the
front of the vehicle.

It affects the grip of the tires, which influences the vehicle's


cornering performance.

θ a : Camber angle

This angle is formed by the centerline of the wheel and the line
that extends perpendicularly from the ground.

Steering axis (Kingpin) inclination


This is the inclination of the kingpin axle, which dampens the
impact from the tires.

θ b: Kingpin angle
This is the inclination of the kingpin axle.

L: Kingpin offset
This is the distance measured along the road surface between the
tire centerline and the point at which the extended line from the
kingpin axle intersects with the road surface.

HINT:
The kingpin angle is the line that links the upper ball joint and the
lower ball joint, and the rotational centerline of the front wheel
when the steering wheel is turned.

Upper ball joint


Lower ball joint

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Frequent Service Job Course Chassis

Caster
This is the inclination of the kingpin axle, which dampens the
impact from the tires.

θ c : Caster angle
This is the angle between the kingpin axle and the plumb line.
This angle creates a force to return the wheels to the straightline
position, thus enabling the vehicle to track straight.

L : Caster trail
This is the distance between the ground contact center of the tire
and the ground contact point of the line that extends from the
kingpin axle.
The ability of the vehicle to drive in a straight line increases
according to the caster trail distance.

Turning radius

This is the turning angle of either front wheel when the steering
wheel is turned.
The inner and outer front wheels turn at different angles so that
they can draw circles around the same center, in order to ensure
the cornering performance of the vehicle.

θo:Turning angle of the outer wheel


θi :Turning angle of the inner wheel
O: Center of turning

Toe angle (Toe-in and Toe-out)

When the vehicle is viewed from the top, both front and rear
wheels generally point inward. This condition is called "toe-in",
and it helps the vehicle track straight. It is called 'toe-out', when
the front wheels point outward.

Toe in
Toe out

(1/1)

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Frequent Service Job Course Chassis

Steering

Steering

In the steering system, the front wheels of a vehicle are steered


by turning the steering wheel. There are two types of steering;
rack-and-pinion type and recirculating-ball type.

Rack-and-pinion type
Changes the rotational movement of the steering wheel into the
left or right movement of steering rack. The construction is simple
and lightweight. The steering is solid, and the steering wheel
response is very sharp.

Steering wheel
Steering main shaft & column tube
Steering gear
Steering rack housing
Pinion
Rack

(1/1)

REFERENCE:
Recirculating-ball type

There are many balls between the worm shaft and the nut at the
sector shaft.

Steering wheel
Steering main shaft & column tube
Steering gear
Steering linkage
Steel balls
Ball nut
Sector shaft
Worm shaft

(1/1)

Brakes

Brakes

The brakes decelerate or stop a vehicle in motion, or prevent a


parked vehicle from moving.

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Frequent Service Job Course Chassis

Foot brakes

Parking brakes

(1/1)

Foot Brakes

Foot brakes are used to control vehicle speed and stop the
vehicle.
Generally, disc brakes are used on the front wheels, and disc
brakes or drum brakes are used on the rear wheels.
Brake pedal
Brake booster
Master cylinder
Proportioning valve (P valve)
Disc brake
Drum brake

(1/3)

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Frequent Service Job Course Chassis

When the brake pedal is depressed, it creates the hydraulic


pressure, and operates as follows.
• Disc brakes:
Stop the rotation the wheels due to the friction which occurs
when the disc brake pad pushes against the disc brake rotor.
• Drum brakes:
The brake shoe expands. This stops the rotation of the wheel
due to the friction which occurs by the pushing of the brake
lining against the brake drum.
Brake pedal
Brake booster
Master cylinder
Disc brake caliper
Disc brake pad
Disc brake rotor
Brake drum
Brake lining
Brake shoe
(2/3)

Brake pedal
Parts controlled by the force of the driver's foot. This force
becomes converted into hydraulic pressure, which acts on the
brake system.
The strength of the braking force is determined by the amount of
pedal effort that is applied by the driver.
It is necessary to inspect the brake pedal free play, height, and the
pedal reserve distance in maintenance.
Brake booster
Device to boost the force that acts on the master cylinder in
accordance with the amount of pedal effort that is applied by the
driver.
The vacuum from the engine intake is used as the source of boost
energy.
Master cylinder
Parts to convert the driver's pedal effort into the hydraulic
pressure.
Reservoir It consists of a reservoir that stores the brake fluid and a cylinder
Cylinder that generates hydraulic pressure.
To front brakes The master cylinder converts the driver's pedal effort into
To rear brakes hydraulic pressure. The hydraulic pressure is then applied to the
disc brake calipers of the front and rear brakes, and to the wheel
cylinders of the drum brakes.
Maintenance items include the replacement of the brake fluid.

(3/3)

Disc Brakes

Push the disc brake pad against the rotation disc brake rotor with
the wheels, and create friction. Controls the wheel rotations by
friction.

Disc brake caliper


The pistons push the disc brake pad against the disc brake rotor
by the hydraulic pressure from the master cylinder.

Before operation
During operation

Disc brake caliper


Disc brake pad
Disc brake rotor
Piston
Fluid

(1/3)

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Frequent Service Job Course Chassis

REFERENCE:
Types of disc brake caliper

Fixed caliper type


A fixed caliper type has a pair of pistons to push the disc brake
rotor in the both sides.

Floating caliper type


A floating caliper type is attached the piston only on one side of
the caliper. Pistons act the hydraulic pressure. If the disc brake
pad is pushed, the caliper slides into the opposite direction of the
piston, and pushes the disc brake rotor from the both sides. As a
result, it stops the rotation of the wheel. There are several kinds of
floating caliper type, depending on the methods to attach the
caliper to the torque plate.

FS type (two pin type)


AD type (one pin, one bolt type)
Pin Bolt Caliper Torque plate PD type (two bolt type)

(1/1)

Disc brake pad


This is the friction material that is pushed against the rotating disc
brake rotor.
Maintenance items include the inspection of the disc brake pad
thickness.

Anti-squeal shim
Prevents unusual noise as the brake pad vibrates at the time of
braking.

Disc brake pad


Anti-squeal shim

(2/3)

Disc brake rotor


This is a metal disc that rotates together with the wheel. There is a
solid type that is made from a single disc rotor, and a ventilated
type that is hollow inside.
There is also a parking drum brake type disc brake rotor.

Solid type
Ventilated type
With drum type

(3/3)

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Frequent Service Job Course Chassis

Drum Brakes

A brake drum rotates together with the wheel. The brake shoes
press against the drum from the inside. This friction controls the
rotation of the wheel.
It is necessary to inspect the brake drum and brake lining.

HINT:
The brake shoes press against the rotating drum from the inside
to get braking power. When pressed in the same direction as the
drum rotates, the shoes make inroads into the rotational direction
by the friction with the drum. As a result, the friction power
increases, which is called self-energizing action.

Wheel Cylinder
There is a piston, which the rubber cup is attached, in the cylinder. This piston transmits the hydraulic pressure to the brake shoe
from the master cylinder, and presses against the brake lining.

Brake Shoe / Brake Lining


The brake lining is the friction material that presses against the roating brake drum, which is put on the surface of the brake shoe.
The leading shoe generates the self-energizing action the direction, which the vehicle moves. The trailing shoe is attached on the
opposite side of the leading shoe.

Brake Shoe / Brake Lining


The brake lining is the friction material that presses against the roating brake drum, which is put on the surface of the brake shoe.
The leading shoe generates the self-energizing action the direction, which the vehicle moves. The trailing shoe is attached on the
opposite side of the leading shoe.

Brake Drum
Drums to rotate with the wheels.

Piston
Parts that get the hydraulic pressure from the master cylinder and press the brake shoe into the brake drum.

Piston Cup
The piston cup is the rubber part that keeps the oilsealed between the wheel cylinder and piston.

(1/1)

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Frequent Service Job Course Chassis

REFERENCE:
Types of the drum brake

Drum brake has different types, depending on the combination of


the leading and trailing shoe. Use properly, depending on the
purpose, with the feature that is generated by the leading and
trailing shoe.

Leading-and-trailing type
Two-leading type
Uni-servo type
Duo-servo type

Fixed wheel cylinder


Fixed anchor
Adjusting cylinder

Red arrow:
rotational direction of the wheel
Pink arrow:
direction that the piston moves

The diagram on the left indicates the color of the brake shoe.
Leading shoe: orange
Trailing show: blue

(1/1)

Parking Brakes

Parking brakes are used mainly when the car is parked.


They mechanically lock the rear wheels.
Maintenance items include the adjustment of the parking brake
lever.

Parking Brake Lever


Operation lever of the parking brake.

Parking Brake Cable


Cable to transmit the power of the parking brake lever to the
parking brake.

Rear Brake
Press the brake shoe (disc brake pad) against the drum (disc
rotor) to fix the vehicle in position.

(1/1)

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Frequent Service Job Course Chassis

REFERENCE:
Parking brake lever types

Lever type
Mainly used in passenger and commercial vehicles.

Stick type
Used in some commercial vehicles.

Pedal type
Used in some passenger and high-grade vehicles. Nowadays the
release is operated with the pedal.

Release lever
Pedal

(1/1)

REFERENCE:
Parking brakes body types

There are several types, depending on the type of rear brakes.

Foot brake sharing type


Drum Brake Type
Pulls the shoe lever with a cable and presses the brake shoe
against the drum, to fix it in position.

Disc Brake Type


Pulls the lever with a cable and presses the disc brake pad
against the disc brake rotor with the piston to fix it in positon.

Devoted parking brake type


Pulls the shoe lever with a cable and press the brake shoe against
the drum to fix the disc brake rotor in position.

Center brake type


Pulls the shoe lever cable a wire and presses the brake shoe
against the drum to fix the propeller shaft in position.

Brake shoe
Shoe lever
Piston
Disc brake pad
Disc brake rotor
Parking brake cable

(1/1)

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Frequent Service Job Course Chassis

Tires

Tires

Among the numerous parts that are used on an automobile, tires


are the only ones that come in contact with the road surface, and
support three basic efficiencies: driving, turning and stopping.
Maintenance items include tire inspection (exterior damage, tread
depth, and wear conditions), adjustment of air pressure, and the
rotation of the tires.

Tread
An outer layer of the tire that protects the carcass and prevents
wear and cuts.
Belt (Rigid Breaker)
A reinforcement belt that is affixed circumferentially between
the tread and the carcass.
Carcass (Cross Plies)
Forms the skeletal structure of the tire and forms the tire.
Inner Liner
A rubber layer that is equivalent to a tube, it is affixed to the
inside wall of the tire.
Bead Wire
Secures the tire on the rim.

Radial tire
Compared to a bias tire, its tread deformation is smaller. Thus, it
has a better grip and cornering performance. Because of its
higher tread rigidity, it is more susceptible to transmitting the road
shocks, and results in a slightly poorer ride comfort.
Bias Tire
Compared to a radial tire, this tire gives a softer ride, but its
cornering performance is slightly inferior.

(1/1)

REFERENCE:
Types and Features of Tires

Tubed tire
Contains a tube that is inflated with air.

Tubeless tire
Has a special rubber layer called an "inner liner" instead of a tube.

Low-profile tire
"Profile" pertains to the contour of the side of the tire, and a "low-
profile" tire has a low cross section with a maximum aspect ratio
*
of 60% .
The sidewalls are low, and the tread deformation when turning is
small, so the cornering force is greatly improved.
*: Aspect ratio = H/W x 100%

Run-flat tire
Tube This tires' sidewalls contain reinforced rubber, so even if a vehicle
Valve equipped with this tire has a puncture while driving, and the air
Inner liner pressure drops to zero, it can continue to travel another 100 km
Side rubber reinforcement (62 mile) at a maximum speed of 60 km/h (37 mph).

Compact spare tire (T type tire)


A temporary tire that is used in an emergency, such as when the
normal tire cannot be used due to a puncture.
It is a high air pressure, narrow bias tire.

(1/1)

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Frequent Service Job Course Chassis

Specification Coding System

The size, performance, and the construction of the tire are


indicated on the sidewall of a tire.
The diagram on the left shows the names of the sizes of the
various areas of a tire.

Tire height
Tire width
Wheel rim diameter
Tire external diameter

(1/2)

REFERENCE:
How to read the tire size

1. Radial-ply tire
2. International standardization organization(ISO) tire coding
system
3. Bias-ply tire
4. Compact space tire(T type tire)

1. Radial-ply tire

- 17 -
Frequent Service Job Course Chassis

2. International standardization organization(ISO) tire coding


system

3. Bias-ply tire

4. Compact space tire(T type tire)

(1/1)

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Frequent Service Job Course Chassis

Aspect ratio
The ratio of the height of the cross section of the tire to the width
(which is rendered 100) is indicated as a percentage (%).

Aspect ratio = / x 100(%)


Tire width
Tire height

• A tire with a high aspect ratio


The cornering performance is slightly poor.
It gives a better ride, and is suited to family cars.
• A tire with a low aspect ratio
It gives a slightly poorer ride. It is better suited to sports cars
because the cornering performance is better.

(2/2)

Disc Wheels

Disc Wheels

A disc wheel is a disc-shaped part to which a tire is mounted. With


the tire, it supports three basic functions: driving, turning and
stopping.

Pressed-steel disc wheel


This wheel is made of pressed steel. It is heavy, but strong.

Cast light-alloy disc wheel


This wheel is made of aluminum. It is lightweight and offers
excellent design performance. Compared to the steel wheel, has
lower shock resistance.

(1/2)

Disc wheels specification coding


The size of the wheel is indicated on the rim of the disc wheel.

Pressed-steel disc wheel


Cast light-alloy disc wheel

Wheel rim width


Wheel rim flange shape
Offset
Wheel rim diameter
Wheel rim center
P.C.D (Pitch Circle Diameter)
Hub mounting surface

(2/2)

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Frequent Service Job Course Chassis

REFERENCE:
How to read the wheel size

*1 : Codes "J" and "JJ" are frequently used, depending on the


shape of the wheel rim flange. The JJ is slightly higher than the J,
which makes the tire less susceptible to coming loose.

(1/1)

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Frequent Service Job Course Chassis

Exercises

Use the Exercises to check your level of understanding for the material in this Chapter. After answering each Exercise,
you can use the reference button to check the pages related to the current question. When you get a wrong answer,
please return to the text to review the material and find the correct answer. When all questions have been answered
correctly, you can go to the next Chapter.

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Frequent Service Job Cource Chassis
Exercise
Question-1
Select the role of each part shown in the illustrations below from statements a) to d).

1. 2.

3. 4.

a) Physically support the axles to ensure a better ride.


b) Support the vehicle through contact with the road surface.
c) Change the direction of travel of the vehicle.
d) Decelerate or stop the vehicle.

Answer: 1. 2. 3. 4.

Question-2
The following illustrations are of the rack-and-pinion type steering device. Select the name of each part from the word
group below.

a) Pinion
b) Steering gear
c) Steering rack housing
d) Rack

Answer: 1. 2. 3. 4.

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