Suspension, Steering, Alignment: Section
Suspension, Steering, Alignment: Section
SUSPENSION, STEERING,
ALIGNMENT 11
THEN AND NOW: STEERING
Some of the early automobiles could reach surpris-
ingly high speeds. From a safety standpoint, the steering
systems used in these vehicles were very primitive. Direct
linkage from a tiller to the drag link could result in a bro-
ken arm when you hit a bump. The first domestic vehicle
equipped with a steering wheel was the 1901 Packard.
Even after the tiller evolved to the less lethal steering
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CHAPTER 63
Suspension
Fundamentals
OBJECTIVES
Upon completion of this chapter, you should be able to:
■ Identify parts of typical suspension systems.
■ Describe the function of each suspension system component.
■ Compare the various types of suspension systems.
KEY TERMS
A-arm control arm monoleaf spring
active suspension system dive overload leaves
adaptive suspension system double-acting shock passive suspension system
aeration absorber rebound
ball joint follower ball joint rigid axle
body roll gas shock shackle
center bolt independent suspension shock absorber
chassis jounce squat
coil spring leaf spring sub-frame
composite spring load carrier ball joint suspension
compression Macpherson strut torsion bar
INTRODUCTION
The vehicle chassis includes the frame, shocks and
springs, steering parts, tires, brakes, and wheels. The sus-
pension system is part of the chassis (Figure 63.1).
There are several suspension designs in use today. Over
the years, there have been many part names associated
with these designs. The names used in this chapter are
those that have become standard. As you read the chapter,
become familiar with the names of the suspension parts.
SUSPENSION
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1180 CHAPTER 63
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Suspension Fundamentals 1181
Cross member
Torsion bar
adjuster bolt
Lower trailing
control arms
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1182 CHAPTER 63
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Suspension Fundamentals 1183
Federal-Mogul Corporation
Rigid axle suspension
Figure 63.10 On a rigid suspension, movement of the
right wheel causes an opposite movement of the left Figure 63.12 Control arms allow the springs to deflect.
wheel.
Federal-Mogul Corporation
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Frame Lower
control arm
Strut rod
Figure 63.13 The strut rod provides stability to a narrow
Independent suspension control arm.
Figure 63.11 When an independent suspension goes
over a bump, only one wheel deflects.
Outer shell
Control Arms
The control arms used with independent suspen-
sions allow the springs to deflect (move up or down).
They are called an A-arm when they are like the ones
shown in Figure 63.12. A narrow control arm style
used on lighter cars has a strut rod, or radius rod, to pro-
vide stability (Figure 63.13).
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1184 CHAPTER 63
Bushing
Bushing
Federal-Mogul Corporation
Wear
occurs
Short/long arm
here
Tim Gilles
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Suspension Fundamentals 1185
Figure 63.18 SLA suspensions allow the track width to remain constant, reducing tire scrub.
Figure 63.19 With control arms of equal length, the tire slides as it goes over a bump, scrubbing the tires and wearing
them out.
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1186 CHAPTER 63
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Suspension Fundamentals 1187
Control
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1188 CHAPTER 63
Eye
Tim Gilles
Piston rod Piston rod
Rebound
Compression
Strut housing
Cartridge
Piston and
valve assembly
Tim Gilles
Piston
Figure 63.27 Cutaway of a Macpherson strut shock and
absorber. valving
Tokico [USA], Inc., Performance Division
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Suspension Fundamentals 1189
■■ SCIENCE NOTE ■■
A basic formula says that the resistance to flow (oil
through the piston) goes up as a square of the velocity.
Aerodynamics engineers try to reduce resistance, while
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1190 CHAPTER 63
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Suspension Fundamentals 1191
Axle Air
assembly inlet
Figure 63.34 Shock absorbers staggered on each side
of the rear axle.
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1192 CHAPTER 63
Shock absorber
Sway Stabilizer link
bar
Federal-Mogul Corporation
links
Sway
bar
Coil spring
bushing
insulator Stabilizer
Figure 63.37 Parts are insulated from each other with bar
rubber bushings.
STABILIZER BAR
A stabilizer bar, also called a sway bar or an anti-roll
bar, is used on the front or rear of many suspensions
(Figure 63.38). It connects the lower control arms on
both sides of the vehicle together, reducing sway and
Follower
Load carrier
Figure 63.40 The location of load carrier and follower ball joints.
Jounce or
Road compression
force bumper
Tension loaded
(or bump stop)
load carrier
Road
Compression loaded force
Figure 63.42 A pivot bearing allows the strut to rotate.
load carrier
Figure 63.41 Tension and compression loaded ball capability of the shock absorbers as well. Most of the
joints. systems have air or conventional springs.
Compressor
Relay
B+
Height Control
sensor
Compressor
Manual
switch
Relay
Air shock
Check suspension
ECC module signal (message Actuator System
acceleration center) diagnostic
sensor relay pigtail
Dual System
damping on/off
actuator switch
Air Ignition
compressor
Brake
Speed sensor sensor
(pressure)
Steering
sensor Rear height Suspension
sensor control
module
Air spring Door open
Figure 63.45 A computer system controls the air springs at each wheel.
Electronically Controlled Shock Absorbers 0.010 second (10 milliseconds). These devices can be
Electronically controlled shock absorbers have variable found on shocks and struts.
valving. The amount of shock damping changes as the Some electronically controlled shocks use a vari-
size of a metered orifice within the shock is manipu- able orifice controlled by gas or air. Normal shock
lated by the computer. An actuating motor on the top absorber valves are used.
of the shock (Figure 63.47) turns a control rod that Shock absorbers deflect in one direction to control
changes the size of the orifice (Figure 63.48). fluid flow:
The newest adaptive systems use solenoid actu- ■ At lower speeds, they operate normally (the valve
ated shock valves, which allow almost instantaneous is fully open). This is the comfort mode, and fluid
changes in the size of a shock’s damping orifice. The flows unhampered through the orifice. The valves
suspension can react to changes in body height in work as normal.
Air spring
Shock
absorber
Rear
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leaf
Ride
spring
height
sensor
Tim Gilles
Figure 63.46 An air spring used with a conventional Figure 63.47 An electronically controlled shock
spring. absorber.
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1196 CHAPTER 63
Electrical
input
Iron Iron
particles particles
© Cengage Learning 2012
Figure 63.49 The viscosity of the magnetic fluid in this MR shock absorber changes very quickly in response to
computer commands.
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Suspension Fundamentals 1197
Nonenergized Energized
winding winding
absorbers and springs are not needed, because the The computer uses signals received from sensors
actuators replace them (Figure 63.51). They provide a to track the position of each actuator. It can sense
smooth ride and yet give the handling characteristics of whether a wheel is in jounce or rebound. It also senses
a vehicle with a stiff suspension. The suspension can be how heavily each wheel is loaded and whether the
programmed by the driver as to the type of ride desired. wheel is turning or pointing straight ahead. The com-
The active suspension is powered by a hydraulic puter sees a bump and immediately releases pressure
pump driven by the engine. It requires about the from a control valve. It can release pressure instantly
same amount of power as a typical power steering or relatively slowly, depending on what the computer
pump during a turn (3–5 horsepower). The high- program specifies. After the suspension absorbs the
speed actuators can raise or lower the vehicle in 0.003 shock, pressure is forced back into the actuator to keep
second (3 milliseconds). As soon as a bump has been the tire contacting the road and maintain ride height.
absorbed by an actuator, pressure is reestablished to
NOTE: In case of a flat tire, the system can be told to raise
keep the wheel in contact with the road and main-
the tire so a jack is not needed.
tain ride height. During hard stops, active suspension
reduces the tendency for the vehicle to dive or lean. Sensors provide the computer with necessary
Power consumed by the system is least when the information regarding extension and compression of
vehicle is riding flat. each actuator and how heavily the vehicle is loaded.
Lateral
acceleration
sensor Yaw
angle
sensor
Valve block
Control unit and accumulator
ABC pump
Longitudinal
acceleration
sensor Level sensors
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1198 CHAPTER 63
REVIEW QUESTIONS
1. Which kind of spring is adjustable? 6. What is the term that describes the softness or
2. What is the name of the suspension type that harshness of the ride?
uses two different length control arms? 7. What kind of shock can be mounted upside down?
3. What is the name of the part that is used to 8. If a small amount of air is not kept in an air
control spring oscillations? shock, what can happen?
4. Hydraulic shock absorbers are sensitive to 9. What is the name of the kind of front
velocity/load (circle one). suspension that has a built-in shock absorber
5. Which shock absorber motion controls the and only one ball joint?
least amount of weight, compression or 10. What is the name of the ball joint design that is
rebound? always trying to pull apart?
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Shock absorbers dampen excess motion by converting motion energy to heat energy through hydraulic friction, thereby controlling the oscillations of springs . They play a critical role in both compression damping, which keeps tires in contact with road surfaces by controlling unsprung weight, and rebound damping, which controls excess chassis motion .
A Macpherson strut combines the spring and shock absorber into one assembly, saving space and reducing weight, whereas a short-and-long arm (SLA) suspension uses two unequal-length control arms arranged in a double-wishbone configuration . Macpherson struts are typically more compact, whereas SLA suspensions can offer better handling due to their geometry .
Rubber bushings separate suspension parts, preventing metal-to-metal contact and allowing for flexibility in movement. This action reduces wear and extends the longevity of suspension components by allowing controlled motion and absorbing vibrations . The twisting capability of bushings also distributes stresses, contributing to a smoother driving experience .
Independent suspension systems provide improved ride quality by reducing the unsprung weight compared to rigid axle suspensions . This configuration ensures that when one wheel goes over a bump, only that wheel moves up or down, whereas in rigid axles, movement of one wheel affects the other wheel, resulting in a rougher ride .
Leaf springs offer significant mechanical advantages by resisting lateral movement and eliminating the need for control arms or struts, which simplifies the suspension design . Leaf springs become progressively stiffer under load, allowing them to provide both a variable spring rate and inherent stability to maintain vehicle alignment during operation .
Ball joints connect the control arm to the spindle, allowing for motion in two directions . They support both the up-and-down movement similar to the bushings and allow the spindle to pivot for steering . This dual functionality is critical for maintaining vehicle stability and steering precision.
Electronically controlled shock absorbers enhance suspension responsiveness by using variable valves that can adjust the size of the damping orifice based on input from sensors . These systems can make nearly instantaneous adjustments, reacting to changes in body height and road conditions to maintain optimal vehicle stability and comfort .
In an independent suspension setup, control arms primarily allow the springs to deflect, accommodating the up and down movement of the vehicle's wheels . They are pivotal in maintaining wheel alignment and providing stability during wheel motion .
Torsion bars can store more energy compared to coil and leaf springs, which is one of their advantages . They do not require much vertical space, allowing the front of the vehicle to be designed lower . This is particularly advantageous in vehicles where space is a constraint, unlike coil springs that need more room for effective operation.
Design strategies to prevent fluid aeration in shock absorbers include using spiral grooves or a flat spiral ring around the reservoir tube to minimize caviation and foam, as well as incorporating gas shocks to control aeration and foaming . Gas shocks pressurize the oil, preventing the air from being released as bubbles under pressure .