Removing and refitting suspension systems on motorsport vehicles
Overview
This standard identifies the competences you need to remove and refit front and rear suspension sub-assemblies and components, such as coil and leaf springs, torsion bars, wishbones, pushrods, pullrods, rockers, dampers uprights/axles, toe links, swinging arms and driveshafts, in accordance with approved procedures.
It covers a range of motorsport vehicles such as single seater, rallying, sports cars, historic and other specific approved competition vehicles. The removal and refitting methods and techniques will include, dismantling the equipment to sub- assembly and component level, protecting exposed components, checking components for serviceability, making mechanical and electrical connections, setting, aligning and adjusting refitted components, tightening fasteners to the required torque, and removing and refitting covers, ducts, hatches and bodywork.
On completion of the removal and refitting activities, you will be required to carry out a range of final checks, tests and adjustments, such as driveshaft plunge, spherical bearing positions, damper pressures and wheel speed sensor gaps.
Your responsibilities will require you to comply with organisational policy and procedures for the removal and refitting activities undertaken, and to report any problems with the process that you cannot resolve or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used are correctly accounted for on completion of the activities, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work as a member of a team, with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. Where team working is involved, you must demonstrate a significant personal contribution during the team activities in order to satisfy the requirements of the standard, and competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying the appropriate removal and refitting techniques and procedures to motorsport suspension systems. You will understand the removal and refitting methods and procedures, and their application. You will know how the equipment functions, the common problems that can occur, the purpose of the individual components and associated defects, in adequate depth to provide a sound basis for carrying out the removal and refitting activities, correcting faults and ensuring that the equipment is replaced to the required standard. You will also have sufficient knowledge of these components to ensure that they are fit for purpose and meet the specifications, thus providing a sound basis for carrying out the refitting activities.
You will understand the safety precautions required when working on motorsport vehicles, especially those for isolating the equipment. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, vehicle manuals and publications to carry out the required work
- remove and refit the components in their correct positions using appropriate methods and techniques
- take suitable precautions to prevent damage to components and surrounding structure
- ensure that the removed components are clean and free from dirt, oil and debris, and that they are in a usable condition, prior to being refitted and tested
- replace and secure the components, using the specified connectors and securing devices
- check that all operations have been completed, and that the finished assembly meets the required specification
- label and store, components that require repair or overhaul
- deal promptly and effectively with problems within your control and report those that cannot be solved
- ensure that work records are completed, stored securely and available to others as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the procedures for obtaining the various types of manual/drawing, job instructions and specifications that are used during the removal and refitting of the suspension sub-assembly, and how to interpret them correctly
- how to identify the components to be used; component identification systems (`lifing' numbers and component orientation indicators).
- the removal and refitting methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be aligned and positioned prior to securing, and the tools and equipment that are used (including jigs and fixtures)
- the various mechanical fasteners and other components that are used (threaded fasteners, lock wire, cable ties, bearings, seals, gaskets and fasteners)
- the application of greases, sealants and adhesives within the removal and refitting activities, and the precautions that must be taken when working with them
- the operational function of the various front and rear suspension components that are used
- the use of torque wrenches and the importance of ensuring that fasteners are adjusted to the required settings
- how to correctly fill dampers and forks with hydraulic fluid, how to bleed brakes, and the correct waste disposal procedure for surplus fluids
- how to adjust steering mechanisms for wheel alignment, bump steer, castor, and camber to meet specifications
- how to handle, remove and refit spherical bearings, wheel bearings, seals and gaskets
- the consumables, tools and equipment used for removal and refitting of the suspension sub-assembly
- the importance of using the specified fasteners for the removal and refitting, and why you must not use substitutes
- dealing with components or fastening devices that are incorrectly assembled, damaged or have other faults
- the quality control procedures to be followed during the removal and refitting operations
- how to conduct any necessary checks to ensure the accuracy and quality of the assembly produced
- how to recognise defects (incorrect assembly, ineffective fasteners, component damage)
- the importance of ensuring that the completed assembly is free from fluid residue and foreign objects
- the methods and equipment used to transport, handle and lift the components into position, and how to check that the equipment is within its current certification dates
- preparations to be undertaken on the components and fixing points, prior to fitting the components into the front and rear suspension sub-assembly
- how to check that the tools and equipment to be used are correctly calibrated, and are in a safe, tested and serviceable condition
- the importance of ensuring that all tools are used correctly, checked and stored after use
- problems with the removal and refitting operations, and the importance of informing appropriate people of non-conformances
- the procedure for the safe disposal of waste materials, scrap components, oils and fluids
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following during the removal and refitting of the motorsport vehicle suspension systems:
- plan the removal and refitting activities prior to beginning the work
- obtain and use the appropriate documentation (such as job instructions, assembly drawings, manuals, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the working area, and ensure that any appropriate environmental conditions can be met
- ensure that the work area is suitably prepared for the removal and refitting activities to take place
- obtain approval to carry out the suspension removal and refitting activities
- position and secure the vehicle, using the correct equipment
- ensure that any required consumables are available
- leave the work area in a safe condition and free from foreign object debris
- return all tools and equipment to the correct location on completion of the activities
Remove and refit components on one of the following types of motorsport vehicle:
- single seater
- sports cars
- other specific approved competition vehicle
- rally
- historic vehicles
Use appropriate methods and techniques to remove and refit motorsport vehicle suspension components, to include fourteen of the following:
removing covers, ducts, hatches and bodywork
re-jigging components when new spherical bearings are fitted
- making an initial judgment of the condition of the suspension (such as damage, missing components)
- releasing stored energy
- replacing 'lifed' components (such as wishbones, uprights, pushrods)
- re-assembling components to sub-assembly level (such as rockers, uprights, axles)
- removing hydraulic hoses and components and protecting exposed hose/pipe fittings
- setting, aligning and adjusting replaced components
- disconnecting electrical plugs and wiring looms
- compressing and securing coil road springs (where appropriate)
- making mechanical connections, and tightening fastenings to the required torque
- dismantling the suspension to an appropriate level
- refitting hydraulic hoses and wiring looms, following the correct routeing
- supporting items of equipment to be removed
- marking and labelling components to aid reassembly
- bleeding fluid systems (where appropriate)
- checking components for serviceability
- coating the suspension, as required (such as paint, oil, etching fluid)
- crack-checking components, and replacing damaged or cracked components
- dynamometer testing and adjusting of dampers
Use five of the following during the removal and refitting activities:
- jigs
- specialist tools
- measuring equipment
- fixtures
- vehicle lifting equipment
- alignment tools
- hand tools
- suspension supports
- non-destructive testing equipment
Remove and refit motorsport suspension components/assemblies, to include twelve of the following:
- uprights/axles
- dampers
- rockers
- toe links
- clevis pins
- trailing arms
- driveshafts
- wheel speed sensors
- live axles
- constant velocity joints
- brake ducts
- anti-roll bars
- hooks/tripod joints
- torsion bars
- drop links
- chains/sprockets
- wishbones
- tie rods
- road leaf springs
- pushrods
- bodywork mounts
- road coil springs
- pullrods
Carry out final checks and adjustments on the refitted suspension system, to include ten of the following:
- checking that all suspension components are free from foreign objects, dirt or other contamination
- checking that the suspension assembly is complete and complies to specification
- checking that all mechanical fixings are secure and have been `torqued' to specification and, where appropriate, that bolt locking devices are fitted
- ensuring that pipes and cables are correctly secured and free from potential chafing
- ensuring that correct alignment, seating, and clearance of components is achieved
- ensuring that spherical bearings have been adjusted to allow for suspension movement
- checking that driveshafts have enough `plunge'
- checking that top-hat bushes have been fitted in the correct positions
- checking that bump-steer spacers have been fitted in the correct positions
- ensuring that dampers are pressured and free from leaks
- checking that brake ducts are of the correct type
- checking that the wheel speed sensor `gap' has been set
- ensuring that life numbers have been listed
- carrying out other specific tests
Check removal and refit of motorsport suspension systems, comply with one of the following:
- race associations vehicle manufacturer's specification
- team/company standards and procedures
- specific vehicle requirements