Inspect and measure rotors; perform needed action.

Lesson Plan for

DIT 180 Brakes

Course HS Title: / DIT 180 Brakes / Program:
KCTCS Courses included in HS Title: (Lesson is prepared for course highlighted.)
KCTCS Course No. / KCTCS Course Title
Introduction/Context / This lesson will introduce students on how to inspect and measure rotors; perform needed action. 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 automobile accident or create customer satisfaction issues.
Prepared By / School / Date:
Grade Level / No. Students / No.IEP's: / Lesson Length:
Task
Inspect and measure rotors; perform needed action.
No. / Objective
1 / Given a vehicle with disc brakes, Students will be able to inspect and measure rotors, perform needed action, and pass a written exam on 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
RST 11-12 2
N-Q-3
N-Q-1
New Generation Science Standards:
HS-PS2-1.
HS-PS3-3.

INSTRUCTIONAL MATERIALS/TECHNOLOGY
Textbooks and Workbooks

Author / Title/ISBN No. / Edition / Publisher / Pages
Duffy / Modern Automotive Technology / 2004 / Goodheart, Wilcox / 1390-1391
Various / Brakes ASE Test Prep / 2013 / Delmar / 33
Various / Brakes Medium/Heavy Truck ASE Test Prep T4 / Fifth / Delmar / 35


Equipment

Quantity / Item / Source
5 / Disc Micrometers (Metric & Standard) / Snap-On
5 / Dial Indicator w/Brackets / Snap-On


Content/Presentation/Demonstration Outline

Instruct students to remove the disc brake rotor, clean and inspect for damage. Have them check for pitting, grooves, heat cracks, or damage on the friction surface of the brake rotor. Inform students that blue spots on the rotor face indicate excessive heat. Tell them to replace the rotor if there is cracking.
Instruct students to measure brake rotor thickness prior to any other rotor repairs. This should be done to make sure the rotor has enough thickness to be serviced. If rotor does not meet minimum thickness requirements, let them know it should be replaced without any further measuring.
Teach students thatrotor thickness is measured across the two friction surfaces. An outside micrometer should be used for this measurement. Tell them that measurements should be taken at several different positions around the rotor. Variations in their measurements indicate would indicate wear and a need for repair. Tell them to consult the service manual for minimum thickness specification and compare to your smallest measurement.
Explain that rotor runout refers to the parallelism of the disc. Before checking lateral runout, explain that if composite rotors are used, they should remove the rotor and clean the back of the rotor and hub surface. This will eliminate any rust or debris that could alter readings. To check runout, tell students to mount a dial indicator to a solid surface. Runout is measured on the outer edge of the friction surface using a dial indicator. Have them mount a dial indicator to the steering knuckle using brackets supplied with dial indicator unit. Tell students to position the dial indicator on the outer edge of the rotor’s friction surface. Instruct them to zero the dial indicator, and slowly rotate the rotor while observing the dial indicator for the maximum runout. Let them know to not forget to add any value below zero that was indicated on the dial. Inform them to consult the service manual for rotor runout specifications.
If runout is excessive, let them know that the rotor can sometimes be indexed on the hub to match high spots on the rotor with low spots on the hub. This may allow for runout to be within spec. Some aftermarket companies manufacture shim kits to correct lateral runout. Explain that shims with different thicknesses can be installed between the rotor and hub to correct lateral runout.
Instruct students to determine what repair procedure is needed for the rotor using the rotor thickness and runout measurements. Tell them that if the disc rotor is not worn beyond specification, truing (or machining) can be performed. Machining the brake rotor involves the use of a brake lathe, which cuts both sides of the rotor in order to produce an even, smooth friction surface. Let them know that disc rotors must be machined in pairs to ensure smooth and even braking. If the rotor does not meet minimum thickness requirements it must be replaced. After machining, tell them to make sure rotor thickness is still within specification.


Applications/Practice

1 / Students will practice this task by measuring a rotor and comparing their measurement to the specifications in the service manual.


Evaluation and feedback Prior to Testing or Lab Work

Objective 1/ Formative assessment / Instructor will observe students as they practice the procedure to assure correct procedure and safety practices are being followed. A checklist should be utilized to chart student progress on the task. Questioning techniques will be utilized as necessary to demonstrate student comprehension / Adaptations and/or accommodations for special needs students will be added if required.


STUDENT ASSESSMENT:(Assess student progress with performance criteria.)

Objective 1/ Summative assessment / written test questions on stated objective / adaptation and/or accommodations for special needs students will be added if required.
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.)