Inspect, remove, replace, and align doors, latches, hinges, tailgates, hatches, liftgates and related hardware
Lesson Plan for
CRT 130-1
NON-STRUCTURAL ANALYSIS AND DAMAGE REPAIR SECTION I
Course HS Title: / Non-Structural Analysis and Damage Repair / Program:KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)
KCTCS Course No. / KCTCS Course Title
Introduction/Context / This lesson will instruct the student on how to inspect, remove, replace, and align doors, latches, hinges tailgates, hatches, liftgates, and related hardware. 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 an Automotive Repair Facility. Entry level technicians need to be able to perform this task to 100% accuracy. Incorrectly performing this task can lead to an automobile accident or create customer satisfaction issues.
Prepared By / School / Date:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Inspect, remove, replace, and align doors, latches, hinges, tailgates, hatches, liftgates and related hardware
No. / Objective
1 / Given the proper tools and instruction, the student will be able to inspect, remove, replace, and align doors, latches, hinges, tailgates, hatches, liftgates and related hardware, and pass a written test covering the task with 100% accuracy.
Connections:
New Common Core:RST 11-12-2
RST 11-12-3
A-CED-4
New Common Core Technical
TD-SYS-1
TD-OPS-3
New Science Standards
HS-PS2-3.
Skills Standards:
AA001
EG011
INSTRUCTIONAL MATERIALS/TECHNOLOGY
Teacher Designed Materials and Other Handouts
Textbooks and Workbooks
Various / ASE Test Prep Non-Structural Analysis and Damage Repair / Third / Delmar / 20
Crandell / Auto Collision Repair and Refinishing / 2014 / Goodheart/Wilcox / 220-221
Equipment
As Needed / Hand Tools / Various
Content/Presentation/Demonstration Outline
Let students know that when the doors on a sedan need adjusting, they should start at the rear door. Since the quarter panel cannot be moved, let them know that the rear door must be adjusted to fit these body lines and the opening. Once the rear door is adjusted, inform them that the front door can then be adjusted to fit the rear door. Next, teach them that the front fender can be adjusted to fit the door.
On hardtop models, let them know that the windows can then be adjusted to fit the weather stripping. Windows are usually adjusted starting with the front and working toward the back. Tell them the front is adjusted to fit the pillar, and the window is then adjusted to it. The rear door window is adjusted to the front window rear edge and the opening for the rear door assembly. Explain that some late-model vehicles have stationary door hinges and arc no longer adjustable. Let them know that damaged hinges will have to be replaced to align front or rear doors properly.
Instruct students that vehicles with hatchback-type trunk lids are usually difficult to align because of their size. Tell students that many lids of this type are nearly horizontal in design, which makes them more prone to water and dust leaks. Let them know that some models use adjustable hinges. Others use welded hinges. Hatchback types also use gas-filled door lift shock assemblies, or springs, one at each tipper corner of the lid. Explain that some play may not be available in the door lift support brackets to allow adjustment of the hatchback trunk lid.
Tell students that most late-model, full-size station wagons have a three-way tailgate. Explain that the three-way tailgate has a unique hinge and locking arrangement that allows the tailgate to be operated as a tailgate with the glass hilly down or as a door. Teach students that before doing any station wagon tailgate alignment, closely examine the area to determine where the misalignment exists. It might be necessary to adjust the tailgate as a regular door. Tell them to closely examine the hinges to determine what adjustments are available. On some vehicles, let students know that the lower left hinge provides up/down as well as in/out adjustments for the tailgate. Some vehicles provide adjustment on the body side of the hinge. Others allow adjustment to the tailgate side of the hinge. Tell students to always refer to the vehicle’s body repair manual for which hinges allow adjustment.
Inform students that sliding doors are found on minivans. They may be made of steel or plastic, and they usually have a window. The sliding door moves on upper and lower rollers. Tell them there may be two latches, front and rear. The latches are operated by rods connected to handles. Let them know that some sliding doors have a remote opening feature. Explain that electrical connections are maintained by contacts rather than wires. Like other doors, sliding doors have weather strips and strikers.
Instruct students that a sliding door is relatively simple to remove from the vehicle. They would either pry or cut open the damaged door if it does not open easily. Then, they would unbolt the upper and lower rollers and remove the door. Tell them to mark the location of the strikers and then remove the strikers from the body of the van. They should next remove the latch rods, glass, and connectors.
Tell students to paint the inside of the door and glass area before installing any parts, then install the latch, rods, glass, and connectors on the replacement door. Instruct them to bolt the new sliding door onto the rollers. With two or three strikers and two or three roller attachment points, let students know that a sliding door has a considerable amount of adjustment. As with other doors, tell them to check the door-to-rocker gap first. Have them move the roller brackets up or down as needed to achieve the proper gap. Tell them to check the gap along the top of the door. If the rocker panel gap is even, this gap should also be even.
Instruct students to make sure the sliding door is flush with the surrounding panels. If necessary, tell them to adjust the roller brackets to make the sliding door flush. They should now install the strikers in their former locations. Have them slide the door to close it. It should glide shut. If the door does not close easily, tell them to oil the rollers and the latches, Instruct them to then check the fit at the rear of the door. Let them know that the door should be flush with the quarter panel. Tell them to move the striker in if the door is positioned out or move the striker out if the door is pointing inward. If the door is too low, have them raise the striker. Have them then check the fit at the front of the door, and adjust the striker for a flush fit. Finally, tell them to check the height and adjust if necessary.
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.)