Inspect power steering pump drive gear and coupling; replace as needed. Inspect, adjust, or replace power steering pump, mountings, and brackets.
Lesson Plan for
DIT 160-161
Suspension and Steering (Diesel-Medium/Heavy Duty Truck)
Course HS Title: / Suspension and Steering (Medium/Heavy Duty Truck) / Program:KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)
KCTCS Course No. / KCTCS Course Title
DIT 160-161 / Suspension and Steering (Diesel-Medium/Heavy Duty Truck)
Introduction/Context / This lesson will instruct the student on how to inspect power steering pump drive gear and coupling, replace as needed, and inspect, adjust, or replace power steering pump, mountings, and brackets. Knowledge of these techniques and the skills required to correct problems associated with this task are necessary for a student to acquire if they wish to compete for high paying, high skilled jobs in a Diesel Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an accident or create customer satisfaction issues.
Prepared By / School / Date:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Inspect power steering pump drive gear and coupling; replace as needed.
Inspect, adjust, or replace power steering pump, mountings, and brackets.
Objective
Given the proper tools and instruction, the student will be able to inspect power steering pump drive gear and coupling, replace as needed, inspect, adjust, or replace power steering pump, mountings, and brackets, and pass a written test covering the task with 100% accuracy.
Connections:
Skills Standards:OH 001
OH 002
OH 003
OD 002
OD 003
OD 005
Common Core Technical Standards:
TD-OPS.2
TD-SYS.2
New Common Core State Standards:
RST 11-12 3
N-Q-3
New Generation Science Standards:
HS-PS2-1.
HS-PS3-3.
INSTRUCTIONAL MATERIALS/TECHNOLOGYTeacher Designed Materials and Other Handouts
Textbooks and Workbooks
Various / Suspension and Steering ASE Test Prep T5 / Fifth / Delmar / 18-19
Equipment
Content/Presentation/Demonstration Outline
Tell students that when inspecting the power steering pump, consideration should be given to the pump
mounting bolts to ensure that the correct torque is applied and mounting brackets checked for signs of movement, cracking, or distortion. If the pump is belt driven, let students know that the belt condition and tension should be checked. Also, the belt pulley should be inspected for wear, damage, and proper alignment.
Teach them that it is necessary to test the system’s pump if there is a lack of hydraulic pressure. Low pressure can be caused either by pump problems or by problems in the steering gear. Pump tests tell the technician which part is causing the problem. Tell students that a complete test of the system’s pump requires testing for both pressure and volume. Flow and pressure meters are installed on the complete system. After testing for both flow capacity and pressure, tell students that they will evaluate the situation.
Inform students that when the power steering pump lacks the ability to perform its primary function properly, is low on fluid or when air is introduced into the system, a whining noise will usually be heard coming from the pump. This is accompanied by increased turning effort, binding, non-recovery, pump overheating, and hard steering.
If pressure is low and the flow is low, let students know that the pump is probably the faulty component. If pressure is low but the flow is normal, chances are that excessive internal clearance in the steering gear, due to wear, is causing the problem.
Tell students that the inspection process should also include looking for external leakage. Let them know that sources for oil leakage are the drive shaft seal, reservoir o-ring seal, high-pressure outlet fitting, and the dipstick cap. Have them inspect the hose condition for cracking, brittleness, leakage, or chafing due to external components rubbing against the hose.
Instruct students to check to see if there is an adequate amount of the correct type of fluid in the reservoir. Tell them to check the condition of the fluid, noting any discoloration. Air in the system will cause the fluid to have a foamy appearance. If the pump is overheated, the fluid will become dark. Also, let them know that if the fluid does become discolored, other problems may exist in the power steering system.
Explain that if internal damage is suspected due to low fluid levels or overheating, the power steering pump must be removed and disassembled to determine the extent of the damage. A damaged power steering pump can be identified by score marks in the pump drive gear. Tell them that elongated mounting holes in the power steering pump bracket may cause a noise while in operation. Worn holes in the power steering pump mounting bracket could cause premature belt wear. Have them refer to the manufacturer service literature for inspection and repair procedures.
Instruct students that when they replace the power steering pump drive on a truck with a diesel engine, it is not necessary to re-time the engine when this replacement process is complete. Further, they should inspect the driven gear for worn or chipped teeth.
Tell them they will perform these tasks when removing and installing a gear-driven power steering pump: They will check pump mounting holes for wear, remove hoses from pump and cap the fittings, replace the o-ring, and bleed the air from the power steering system.
Applications/Practice
Evaluation and feedback Prior to Testing or Lab Work
STUDENT ASSESSMENT:(Assess student progress with performance criteria.)
IMPACT--Reflection/Analysis of Teaching and Learning: (How did students’ progress in relation to the state objectives? Was the instruction successful? Analyze samples of student work particularly that which is unsatisfactory, for the purpose of planning further instruction.)
REFINEMENT--Lesson Extension and Follow-up: (To be filled in as the lesson is modified during initial planning and/or during the teaching learning process.)