Chapter 8

Hand Tools
 Introduction
• Shop performance
– Purchase and use of tools
– Shop equipment
– Shop tasks
– Equipment and tool maintenance
 LO 8-1: Practice basic hand tool safety.
• Safety guidelines
– Safe attitude
– Avoid accidents
– Safety and
operation
procedures
 LO 8-1: Practice basic hand tool safety.
• Work safe; stay safe
– Safety first when using tools
– Incorrect usage of hand and power tools can lead to injury
– Follow instructions
– Shop policy
– Personal protective equipment (PPE)
 LO 8-1: Practice basic hand tool safety.
• Safe handling/use of tools
– Prevent injury and damage
– Inspect tools prior to and after use
– Check manufacturer and shop procedures
– Proper storage
• Refer to Skill Drill 8-1: Safe Handling and Use of Tools
 LO 8-1: Practice basic hand tool safety.
• Tool usage
– Fundamental tasks
– Work easier, safer, or more
efficiently
– Seek assistance with using
heavy tools
– Correct manual handling
techniques
– Select correct tool
 LO 8-1: Practice basic hand tool safety.
• Lockout/tagout
– Safety practices and procedures
– Minimize risk of technicians using unsafe tools, equipment, or materials
LO 8-1: Practice basic hand tool safety.
 LO 8-1: Practice basic hand tool safety.
• Tool storage
– Hand tools, air tools, measuring
tools, and electrical meters
– Add to over time
– Keep tools secure
– Easy access during use
– Strong and secure
 LO 8-1: Practice basic hand tool safety.
• Shared tool storage
– Centralized
– Specialty tools and equipment
– High-cost equipment
– Not portable equipment
• Refer to Skill Drill 8-2:
Identifying Tools
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Basic hand tools
– Personal tools
– New fasteners, wire harness
terminals, quick-connect fittings
for fuel and other lines
– New technologies require
different types
– Update toolbox regularly
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Size designations
– Tools, measuring instruments,
and fasteners
– Standard: U.S. Customary
System (USCS)
– Metric system
– Markings
– Possibly on packaging
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Identify size designations
– Examine for markings
– Identify as standard or metric
– Refer to manufacturer
specifications, if necessary
– Use measuring devices, if
necessary
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Wrenches
– Tighten and loosen nuts and
bolts
– Box-end wrench
– Open-end wrench
– Combination wrench
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Box-end wrench
– Fits fully around head of bolt or
nut
– Grips each point at corners
– Ends are bent or offset
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Open-end wrench
– Open on the end
– Two parallel flats only grip two
points of the fastener
– Different-sized heads on each
end or same size with different
angles
– Good in tight spaces
– Only firmly tightened fasteners
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Combination wrench
– Versatile and popular among
technicians
– Same sized, open-end head on
one end
– Box-end head on other end
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Flare nut wrench
– Also known as flare tubing
wrench or line wrench
– Variation on open-end wrench
– Not as strong as box-end wrench
– No tight fasteners
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Open-end adjustable wrench
– Crescent wrench
– Adjustable
– Movable jaw
– Adjusting screw
– Weaker than fixed wrench
– May slip
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Ratcheting box-end wrench
– Does not require removal of tool
to reposition it
– Inner piece fits over and grabs
points on fastener
– Rotates in one direction and
locks in the other
– Do not overstress
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Ratcheting open-end wrench
– No moving parts
– Partially removed side catches
fastener point
– For blind spaces
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Pipe wrench
– Special
– Grips pipes
– Exerts a lot of force to turn pipes
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Oil filter wrench
– Special
– Grabs filter
– Gives extra leverage to remove
tight oil filter
– Not for filter installation
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Choosing a wrench
– Tightness of fastener
– Available room to turn
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Sockets
– Adaptable and easy to use
– When top of fastener is
accessible
– Fit snugly onto fastener
– Grip all six corners
– Purchased in sets
– Fit a particular size nut or bolt
– Drive size determines twisting
force
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Socket classification
– Standard or metric
– Size of drive used to turn it
– Number of points
– Depth of socket
– Thickness of wall
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Impact sockets
– Really tight fasteners
– Impact wrench exerts more
torque than turning by hand
– Thicker walled than standard
sockets
– Six points to withstand forces
generated by impact wrench
– Grip fastener more securely
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Sockets
– Six- and 12-point sockets fit
heads of hexagonal-shaped
fasteners
– Four- and 8-point sockets fit
square-shaped fasteners
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Socket depth
– Standard: for most nuts
– Deep: fits over deep stud or bolt
to reach nut
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Similar tools
– Square drive
– Replace sockets
– Crow’s foot wrenches
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Accessory sockets
– Purchased in sets
– Different capabilities
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Socket drivers
– Handle
– Breaker bar
– Extension
– Flexible joint
– Speed brace
– Lug wrench
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Ratchet
– Most common socket handle
– Makes easy work of tightening or
loosening a nut
– Little pressure
– Coarse-tooth ratchet
– Fine-tooth ratchet when room to
swing handle is small
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Sliding T-handle
– For heavier tightening and loosening
– Connection between socket and accessory made by a square drive
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Extensions
– Easier access
– Different lengths
– Can be connected
– Socket remains on fastener
– Drive point extended to where
handle can attach
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Flexible joint
– Applies turning force in an angle
– Move fastener without being in line
LO 8-2: Describe the types and uses of basic
wrenches and sockets.
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Speed brace
– Fastest way to spin a fastener on
or off a thread by hand
– Used to remove an already
loosened fastener or to run the
fastener onto the thread until it
begins to tighten
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Lug wrench
– Permanently attached special-
sized lug nut sockets
– Common model has four
different-sized sockets
– Impact wrench used if it does not
remove nuts
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Torque wrench
– Tension wrench
– Tighten to predetermined torque
– Follow manufacturer
specifications
– Fastener gets proper clamping
pressure and will not come loose
– Torque specifications: foot-
pounds (ft-lb), inch-pounds (in-
lb), or Newton meters (N·m)
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Torque wrench: beam style
– Simplest
– Least expensive
– Spring steel beam flexes under
tension
– Smaller fixed rod indicates
amount of torque on a scale
mounted to the bar
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Torque wrench: clicker style
– Adjustable clutch inside
– Clicks when preset torque is
reached
– Can be set
– Higher torque = louder click
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Torque wrench: dial style
– Turns a dial
– Dial indicates applied torque
– Must have visual of dial
 LO 8-2: Describe the types and uses of basic
wrenches and sockets.
• Torque wrench: electronic
– Spring steel bar
– Electronic strain gauge measures
applied torque
– Preset torque reached = audible
signal
 LO 8-3: Describe other basic hand tools.
• Pliers
– Hand tool
– Steel
– Hold, cut, or compress materials
– Jaws
– Cutting surface
– Handles
 LO 8-3: Describe other basic hand tools.
• Types
– Slip-joint
– Combination
– Arc joint
– Needle-nose
– Flat-nose
 LO 8-3: Describe other basic hand tools.
• Combination pliers
– Most commonly
– Two gripping surfaces: flat and rounded objects
– Grip and cut
– Applied force multiplied in strong jaws
 LO 8-3: Describe other basic hand tools.
• Arc joint pliers
– Moveable pivot, Channellocks
– Wider grip and tighter squeeze
for use on big parts
 LO 8-3: Describe other basic hand tools.
• Needle-nose pliers
– Long, pointed jaws
– Reach into tight spots
– Hold small items other pliers
cannot
 LO 8-3: Describe other basic hand tools.
• Flat-nose pliers
– Flat and square end
– Bend wire or sheet steel accurately along a straight edge
 LO 8-3: Describe other basic hand tools.
• Diagonal cutting pliers
– Cutting wire or cotter pins
– Most common cutters
– No hard or heavy-gauge
materials
 LO 8-3: Describe other basic hand tools.
• End-cutting pliers
– Nippers
– Cutting edge at right angles to
length
– Cut through soft metal objects
that stick out
 LO 8-3: Describe other basic hand tools.
• Snap ring pliers
– Metal pins fit in holes of a snap
ring
– Internal or external
 LO 8-3: Describe other basic hand tools.
• Flat-nose snap ring pliers
– No hole on snap ring
– Snap ring cut at angle
– Use safety goggles
 LO 8-3: Describe other basic hand tools.
• Locking pliers
– Vise grips
– General-purpose pliers
– Clamp and hold one or more
objects
– Free up hands
– Adjustable
 LO 8-3: Describe other basic hand tools.
• Allen wrenches
– Allen or hex keys
– Tighten and loosen fasteners
with Allen heads
– Fastener with internal hexagonal
recess
– Best grip on a screw or bolt
– Hexagonal bar with a right-angle
bend at one end
– Fit tight spots
LO 8-3: Describe other basic hand tools.
 LO 8-3: Describe other basic hand tools.
• Screwdrivers
– Must match tip with slot or recess
in fastener head
– Less secure drip than wrenches
 LO 8-3: Describe other basic hand tools.
• Flat-blade screwdriver
– Most common
– Flat tip or blade
– Requires snug fit
– Varied sizes and lengths
– Blade should taper at end
– Support shaft while turning
 LO 8-3: Describe other basic hand tools.
• Phillips head or Pozidriv
screwdriver
– For screw or bolt with a cross-
shaped recess
– Centered on fastener
– Four common sizes
 LO 8-3: Describe other basic hand tools.
• Offset screwdriver
– If little room to turn
– Offset ends used alternately
– Tips look identical
– One tip at 90-degree angle to the
other
 LO 8-3: Describe other basic hand tools.
• Ratcheting screwdriver
– Popular screwdriver handle
– Removable flat and Phillips tips
– Ratchet inside handle
– Blade turns in only one direction
– Direction depends on slider
setting
 LO 8-3: Describe other basic hand tools.
• Impact driver
– When screw or a bolt is
rusted/corroded
– Screw/bolt is overtightened
– Can apply more force
 LO 8-3: Describe other basic hand tools.
• Magnetic pickup tools
– Grab items in tight spaces
– Telescoping stick with magnet
attached on a swivel joint
– Pick up screws, bolts etc.
• Mechanical fingers
– Extract or insert objects in tight
spaces
– Pick up nonmagnetic objects
 LO 8-3: Describe other basic hand tools.
• Magnetic tray
– Parts retention system
– Prevent lost tools and small parts
– Variety of shapes and size
– Stick to surface set on
– Magnetically hold tools and
fasteners
 LO 8-3: Describe other basic hand tools.
• Silicone parts tray
– Grypmat®
– Soft = no damage to surface
– Don’t slide off easily
– Variety of shapes and sizes
– Different compartments
 LO 8-3: Describe other basic hand tools.
• Bolt cutters
– Cut heavy wire, non-hardened
rods, and bolts
– Their compound joints and long
handles give the leverage and
cutting pressure that is needed
for heavy gauge materials
 LO 8-3: Describe other basic hand tools.
• Tin snips
– Like scissors
– Cut thin sheet metal
– Lighter versions make it easy to
follow gasket outline
– Straight blades
– Pair of left- or right-handed
curved blades for cutting unusual
shapes
 LO 8-3: Describe other basic hand tools.
• Aviation snips
– Cut soft metals
– Easy to use
– Handles are spring-loaded in
open position
– Double pivoted for extra leverage
 LO 8-3: Describe other basic hand tools.
• Pry bars
– Constructed of strong metal
– Used as a lever to move, adjust,
or pry
– Variety of shapes and sizes
– Tapered end bent slightly
– Plastic handle on other end
– For applying force to tension
belts or for moving parts into
alignment
 LO 8-3: Describe other basic hand tools.
• Roll bars
– Pry bar
– Sharply curved and tapered end
for prying
– End tapered to a dull point for
aligning
 LO 8-3: Describe other basic hand tools.
• Gasket scrapers
– Hardened, sharpened blade fitted
on end
– Comfortable handle on other end
– Remove gasket without
damaging component’s sealing
face
LO 8-3: Describe other basic hand tools.
 LO 8-3: Describe other basic hand tools.
• Files
– Hand tools with teeth facing in
one direction
– Remove small amounts of
material from workpiece surface
– Different number of teeth
determine material removed
 LO 8-3: Describe other basic hand tools.
• Files grades
– Rough: quick removal of material
– Coarse bastard: rough out or remove
material quickly
– Second-cut: good all-round
intermediary file; leaves smooth finish
– Smooth: finishing file provides smooth
final finish
– Dead smooth: 100 teeth per inch;
create a fine finish
 LO 8-3: Describe other basic hand tools.
• Safe edge files
– Flat, with smooth edge
– No teeth
• Warding file
– Thin
– Work in narrow slots
 LO 8-3: Describe other basic hand tools.
• Square file
– Square or rectangular hole
– Teeth on all sides
• Three-sided triangular file
– Three sides
– Cut into corners without removing
material from sides
 LO 8-3: Describe other basic hand tools.
• Curved files
– Half-round: shallow, convex surface
– Round: make holes bigger
 LO 8-3: Describe other basic hand tools.
• Thread file
– Clean clogged or distorted threads
– Standard or metric configurations
– Must use correct face
 LO 8-3: Describe other basic hand tools.
• File card
– Clean clogged files
– Short steel bristles
– Rub file with chalk first
 LO 8-4: Identify basic hammers and struck
tools.
• Ball-peen (engineer’s) hammer
– Common
– Head is hardened steel
– Rounded face
– Punch or chisel driven with the flat
face
– Used for flattening or peening a rivet
 LO 8-4: Identify basic hammers and struck
tools.
• Steel hammer
– Used to hit chisels
– A lot of force
– Soft-faced hammers for softer metal
• Soft-faced hammer heads
– Rubber
– Plastic
– Brass
– Copper
 LO 8-4: Identify basic hammers and struck
tools.
• Sledgehammer
– Used when a large chisel needs a
strong blow
– Heaviest type of hammer used one-
handed
• Dead blow hammer
– Does not to bounce back during a hit
– For working on vehicle chassis or
when dislodging stuck parts
 LO 8-4: Identify basic hammers and struck
tools.
• Hard rubber mallet
– Special-purpose tool
– Rubber head
– For moving things into place without
causing damage
 LO 8-4: Identify basic hammers and struck
tools.
• Cold chisel
– Most common
– Cut cold metals
– Flat blade
– Tempered and hardened cutting
end
– Softer head
– Remove bolts with rounded-off
heads
 LO 8-4: Identify basic hammers and struck
tools.
• Cross-cut chisel
– Sharpened edge across blade
width
– Narrowed stock
– Gets in grooves
– Cleaning out or making keyways
 LO 8-4: Identify basic hammers and struck
tools.
• Spring-loaded cold chisel
– Tight spaces
– Three parts: chisel, weighted
hammerhead, and spring in
tension
 LO 8-4: Identify basic hammers and struck
tools.
• Punches
– When hammer head is too large to strike without damaging adjacent parts
– Transmits blow from hammer to one point
– Prick punch
– Center punch
– Drift punch
– Pin punch
 LO 8-4: Identify basic hammers and struck
tools.
• Prick punch
– Sharp tip
– Mark points needed to be drawn
on an object
– Scribe intersecting lines between
given points
 LO 8-4: Identify basic hammers and struck
tools.
• Center punch
– Bigger indentation centers a drill
bit where hole will be drilled
– Used with hammer or operate
automatically
– Spring and weighted hammer
inside back end
 LO 8-4: Identify basic hammers and struck
tools.
• Drift punch
– Starter punch
– Gets pin moving
– Tapered shank
– Slightly hollow tip
 LO 8-4: Identify basic hammers and struck
tools.
• Pin punch
– Drives out pins or rivets
– For tight pins
– Long slender shaft
– Straight sides
– Various diameters
 LO 8-4: Identify basic hammers and struck
tools.
• Wad or hollow punches
– Most efficient tool to make a hole
in soft sheet material
– Use end grain of a wooden block
under work area
 LO 8-4: Identify basic hammers and struck
tools.
• Number and letter punches
– Mark engine components
– Boxed sets
– Must be square with surface
being worked on
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Taps and dies
– Form threads in metal
– Pieces can be fastened
together
– Tap cuts female threads
– Die cuts male threads
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Taper taps
– Narrows at tip
– Easy to start straight on new
hole
– Use less force
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Intermediate tap
– Plug tap used as a starter tap
for a new hole
– More aggressive than a taper
tap
– Most common
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Bottoming tap
– Cut threads to bottom of a
blind hole
– Holes with threads that need
extension
– Not a starting tap
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Thread chaser
– Clean up existing threads of a
hole
– No cutting
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Dies
– Cut external threads on a
metal shank or bolt
– Adjust thread fit by adjusting
die
– Loose-fitting threads strip
easily
– Tight-fitting threads increase
torque required to turn bolt
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Using taps and dies
– Turned with tap handle
– T-shaped tap handle to cut a
thread in an awkward space
• Incorrect use
– Fracture and break
– Holes don’t thread correctly
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Die stock
– Octagonal recess
– Die held in die stock
– Cut a new thread on a blank
rod or shaft
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Tap drill chart
– Determines hole diameter
– Shows what drill size is
needed for a particular tap
– Taps made for any given bolt
size
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Screw extractors
– Remove screws, studs, or
bolts broken off in threaded
holes
– Different types
• Extractor size markings
– Size range of screws
– Size of hole to be drilled
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Extractor types
– Coarse left-hand tapered
thread formed on its body
– Some use hardened, tapered
square shank
– Straight-sided, vertically
splined, round shaft screw
extractor
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Bench vise
– Sawing, filing, or chiseling
– Serrated jaws
– Pair of soft jaws prevent
damage
– Aluminum or other soft metal
– Rubber-type surface
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Offset vise
– Jaws set to one side
– Can hold long components
vertically
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Drill vise
– Hold material on a drill
worktable
– Slots on worktable
– Bolted in place
– Secure
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• C-clamp
– Hold parts together for
assembly, drilling, or welding
– Portable
– Retract disc brake caliper
pistons
– Reach around different
shaped pieces
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Pullers
– Remove bearings, bushings,
pulleys, and gears
– Most common have two or
three legs that grip part for
removal
– Specialized for different tasks
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Gear pullers
– Connect to component
externally or internally
– Three main parts: jaws, cross-
arm, and forcing screw
LO 8-5: Identify and use basic taps, dies, and
specialty tools.
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Forcing screw
– Long, fine-threaded bolt
– Applied to center of cross-arm
– Lots of force to component
– Interchangeable feet
– Tapered cone-style foot
– Flat-style foot
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Cross-arm
– Four arms
– Three arms spaced 120
degrees apart
– Fourth arm positioned 180
degrees apart from one arm
– Used as two- or three-arm
puller
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Using gear pullers
– Remove component from shaft or hole
– Require force
• Refer to Skill Drill 8-3: Using Gear Pullers
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Flaring tools
– Tube flaring tool
– Flare end of tube for connecting
• Single flare: tubes carry low pressures like a fuel line
• Double flare: higher pressures like in brake system
• ISO flare
– Bubble flare
– Metric version used in brake systems
LO 8-5: Identify and use basic taps, dies, and
specialty tools.
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Flaring tool components
– Set of bars with holes match
tube end diameter
– Yoke drives a cone into mouth
of tube
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Tubing cutter
– Cut pipes and metal tubing
– Neater than saw
– Larger version for exhaust
pipes
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Using flaring tools
– Correct tube length protrusion
– Use flaring button if needed
– Clamp tightly
• Refer to Skill Drill 8-4: Using Flaring Tools
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Riveting tools
– When fastener doesn’t have to be
easily removed
– Various types
– Components don’t vibrate loose
• Pop rivet guns
– Occasional riveting of light
materials
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Blind rivet
– Two main pieces: finished rivet
and mandrel
– No need to access other side
of hole
– May be plugged shut
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Rivet anatomy
– Body forms finished rivet
– Mandrel discarded after
riveting
• Mandrel head
– Bigger than hole through body
– Makes body swell tightly
against hole
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Using riveting tools
– Join two pieces of material together
– Rivet gun
– Rivets
– Drill
– Properly sized drill bit
– Materials to be riveted
 LO 8-5: Identify and use basic taps, dies, and
specialty tools.
• Using riveting tools
– Consider diameter, length, and rivet material
– Drill pilot holes through metal to rivet
• Refer to Skill Drill 8-5: Using Riveting Tools
Skill Drills
Skill Drill 8-1: Safe Handling and Use
of Tools.
Skill Drill 8-1: Safe Handling and Use of Tools.
1. Select the correct tool(s) to
undertake tasks.
Skill Drill 8-1: Safe Handling and Use of Tools.
2. Inspect tools prior to use to ensure
that they are in good working
order. If tools are faulty, remove
them from service according to
shop procedures.
Skill Drill 8-1: Safe Handling and Use of Tools.
3. Clean tools prior to use, if
necessary.
Skill Drill 8-1: Safe Handling and Use of Tools.
4. Use tools to complete the task
while ensuring that manufacturer
and shop procedures are followed.
Always use tools safely to prevent
injury and damage.
Skill Drill 8-1: Safe Handling and Use of Tools.
5. Ensure that tools are clean and in
good working order after use.
Report and tag damaged tools,
and remove them from service,
following shop procedures.
Skill Drill 8-1: Safe Handling and Use of Tools.
6. Return tools to their correct
storage locations.
Skill Drill 8-2: Identifying Tools.
 Skill Drill 8-2: Identifying Tools.
1. Create a list of tools in your toolbox and identify their
application for automotive repair and service.
 Skill Drill 8-2: Identifying Tools.
2. Look through the shop’s tool storage areas, and create a
list of the tools found in each storage area.
 Skill Drill 8-2: Identifying Tools.
3. Identify their application for automotive repair and service.
Skill Drill 8-3: Using Gear Pullers.
 Skill Drill 8-3: Using Gear Pullers.
1. Examine the gear puller you have
selected for the job. Identify the
jaws; there may be two or three of
them, and they must fit the part
you want to remove. Be careful to
select the correct foot on the end
of the forcing screw. Finally, select
the right wrench or socket size to
fit the nut on the end of the forcing
screw.
 Skill Drill 8-3: Using Gear Pullers.
2. Adjust and fit the puller. Adjust the
jaws and cross-arms of the puller
so that it fits tightly around the part
to be removed. The arms of the
jaws should be pulling against the
component at close to right
angles.
 Skill Drill 8-3: Using Gear Pullers.
3. Position the forcing screw. Use the
appropriate wrench to run the
forcing screw down to touch the
shaft. Check that the point of the
forcing screw is centered on the
shaft. If not, adjust the jaws and
cross-arms until the point is in the
center of the shaft.
 Skill Drill 8-3: Using Gear Pullers.
4. Tighten the forcing screw slowly
and carefully onto the shaft. Check
that the puller is not going to slip
off-center or off the pulley.
Readjust the puller if necessary.
 Skill Drill 8-3: Using Gear Pullers.
5. If the forcing screw and puller jaws
remain in the correct position,
tighten the forcing screw, and pull
the part off the shaft.
 Skill Drill 8-3: Using Gear Pullers.
6. You may sometimes have to use a
hammer to hit directly on the end
of the forcing screw to help break
the part loose.
Skill Drill 8-4: Using Flaring Tools.
 Skill Drill 8-4: Using Flaring Tools.
1. Choose the tube you will use to
make the flare, and put the flare
nut on the tube before creating the
flare.
 Skill Drill 8-4: Using Flaring Tools.
2. Match the size of the tube to the
correct hole in the tubing clamp.
 Skill Drill 8-4: Using Flaring Tools.
3. Holding the flaring tool, put the tube in the
clamp. Position the tube so that the correct
length is showing through the tool. If you
are conducting a double flare, use the
correctly sized flaring button to ensure that
the proper length of the tube is sticking up
above the top of the clamp. Tighten the
two halves of the clamp together using the
wing nuts. Make sure that the tool is tight
enough to clamp the tube so that it will not
slip.
 Skill Drill 8-4: Using Flaring Tools.
4. Put the cone and forming tool over
the clamp, and turn the handle to
make the flare. If you are doing a
double flare or ISO flare, place the
button in the end of the tube,
install the cone and forming tool,
and turn the handle to make the
bubble. Remove the button from
the tube.
 Skill Drill 8-4: Using Flaring Tools.
5. If this is an ISO flare, inspect it to
see if it is formed correctly. If it is a
double flare, put the cone and
forming tool back on the clamp,
and tighten the forming tool handle
to create the double flare.
 Skill Drill 8-4: Using Flaring Tools.
6. Remove the tube from the clamp,
and check the flare to ensure that
it is free of burrs and is correctly
formed.
Skill Drill 8-5: Using Riveting Tools.
 Skill Drill 8-5: Using Riveting Tools.
1. Select the correct rivet for the
components you are riveting.
Make sure that the rivet is the
correct length.
 Skill Drill 8-5: Using Riveting Tools.
2. Verify that the pilot holes in the
material are the proper size.
Remove any burrs.
 Skill Drill 8-5: Using Riveting Tools.
3. Make sure that the correctly sized
nosepiece for the rivet size is fitted
to the rivet tool.
 Skill Drill 8-5: Using Riveting Tools.
4. Insert the rivet into the gun, and
push the rivet through the
materials to be riveted. Hold firm
pressure while pushing the rivet
into the work.
 Skill Drill 8-5: Using Riveting Tools.
5. Operate the rivet tool to compress
the rivet. Continue this process
until the rivet stem or shank
breaks away from the rivet head.
 Skill Drill 8-5: Using Riveting Tools.
6. Check the rivet joint to ensure that
the pieces are firmly held together.
 Credits
• Unless otherwise indicated, all photographs and illustrations are under
copyright of Jones & Bartlett Learning, LLC.