ASE Practice Test (B3: Non-Structural Analysis & Damage Repair)

Question 1

When straightening a damaged outer door skin, a technician should work from the:

Accepted Answer

Edges of the damage inward toward the center

Answer

When straightening sheet metal damage, always work from the outer edges of the damaged area inward toward the center (highest point). This technique relieves tension at the perimeter first, allowing the metal to return to its original shape without creating additional distortion.

Question 2

A plastic bumper cover has a stress crack but is not torn through. The recommended repair method is:

Accepted Answer

V-groove the crack, weld with plastic welding rod, and finish with adhesive

Answer

For stress cracks in plastic bumper covers, the proper repair is to V-groove the crack with a die grinder, then plastic weld using a compatible welding rod and plastic welder. The repair is then feathered, primed, and painted. Fiberglass is not compatible with most OEM plastics.

Question 3

A replacement hood has been installed but the rear corners are sitting too high compared to the fenders. The adjustment needed is:

Accepted Answer

Shim the rear of the hinges downward

Answer

Hood height at the rear corners is controlled by the hinge attachment points. Shimming or adjusting the rear of the hinges downward will lower the rear hood corners to align with the fenders. Hood bumpers affect the front height, and the latch controls horizontal fit.

Question 4

Before applying polyester body filler, the technician should ensure the bare metal is:

Accepted Answer

Sanded to 80-grit bare metal and free of rust and contamination

Answer

Polyester body filler requires direct adhesion to clean, bare metal. The surface must be sanded to 80-grit to provide mechanical adhesion, and all rust, oil, and contaminants must be removed. Applying filler over primer reduces adhesion and can lead to delamination.

Question 5

A technician measures a door gap at the top and finds it is 8mm, while the gap at the bottom is 4mm. This indicates the door needs to be adjusted:

Accepted Answer

Moved rearward at the top hinge

Answer

The top gap is wider than the bottom, meaning the top of the door is too far rearward (or the bottom is too far forward). Moving the door forward at the top hinge will close the top gap and equalize the spacing. Door gap adjustment is always done at the hinge attachment points.