Rally Service Crew

During a stage rally, there are scheduled times for service that needs to be performed in a limited amount of time (usually ranging from 20 to 60 minutes). Each crew is assigned a role (or multiple roles) and we use a board to make sure nothing has been overlooked.  Here is the document describing each crew role:

General service procedure

See the video below for the general organization and service procedure.

1.       Get service in/out time

2.       Have gas cans ready in refuel area

3.       Raise car on QuickJacks

4.       Fire suppression pin in

5.       Check play in wheels/tie rods/balljoints

6.       Remove all wheels and perform service

7.       Put wheels back on

8.       Lower Quickjack

9.       Torque wheels

10.   Head to refuel

Crew Chief

 See the video below for the crew chief duties

General duties:

·       Reads the racing series general rules about service (CARS 2023 rulebook, check section 18 Service Crews: https://carsrally.ca/wp-content/uploads/2015/09/CARS-2023-En-Rule-Book-Ver-12.pdf)

·       Reads the supp regs and the service book, knows tools and spare parts location and organization

·       Makes sure the crew went to registration and signed their waiver

·       Takes the car to scrutineering (with driver/codriver gear ready)

·       Is familiar with the rules and turbo restrictor inspection (see video)

·       Makes sure service area is ready with tarp, Quickjacks, compressor, tools, etc…

·       Assigns crew roles, prioritizes tasks, briefs crew on their tasks

·       Provides help/guidance during service to all crew members to complete service in allowed time

Service duties:

1.       Gather information from codriver before entering service

2.       Plan for refuel (gas cans ready at refuel with fire extinguisher, crew assigned for refuel)

3.       Make sure fire suppression pin is in when getting in service

4.       Coordinate crew to lift car on QuickJacks

5.       Check play in wheels/tie rods/balljoints as soon as car is in the air

6.       Prioritize inspections/repairs based on reports from crew

7.       Underbody inspection (fender liners/skidplate/exhaust)

8.       Transmission/driveshaft/rear diff visual inspection (leak/damage)

9.       Inspect axle/ axle boots

10.   Check axle nut (32mm)

11.   Ensure all the points are checked

12.   Check LED light bar and interior lights before night stages

13.   Check the hood pins

14.   Fire suppression pin out when leaving service

15.   Make sure crew is at refuel at required time

16.   Help with other car if needed as soon as service is complete

17.   Make sure tarp is cleaned up if needed after service

Tire/Wheel crew

1.       Remove wheels
2.       Inspect wheels/tire for wear/damage (signal any rubbing to crew chief)
3.       Clean inside of rims from dirt with scraper, inspect for excessive damage from scrap. Check the BeadBuster video if you need to clean the bead:
4.       Inspect fender liner (at front of trailer or truck bed if new one needed. Check the fender liner and wiring protection video.
5.       Inspect mud flaps (box #3 if hardware needed)
6.       Check with driver for tire choice
7.       Check tire pressures (30 psi hot for gravel – 36front/30rear for snow tires)
8.       Reinstall wheels (when brake/suspension service is complete)
9.       Torque lug nuts (80 ft.lbs)
10.   Check spare tires and toolboxes in the trunk
11.   Make sure windshield and side windows are clean

See the video below:

Fluid crew

Fluids are in box #4 (big black box with yellow cover)

1. Check engine oil

2. Check coolant

3.  Check power steering fluid

4.  Check brake fluid

5.  Check wiper fluid

6.  Check battery for tightness

7.  Inspect engine belt for tension & wear

8.  Refill CamelBaks (also CoolShirt cooler if if used)

See the video below:

Brake crew

Most of the brake hardware is in boxes #6 and #7. The spare rotors and calipers are on the wall of the trailer. ABS sensors are needed to run our center differential controller (DCCD). 

1.       Inspect rotor/pads

2.      Inspect pin/pin lock/springs for wear

3.      Caliper: Inspect caliper for damage + caliper bolts for tightness

4.      Inspect brake line for damage + banjo bolt for tightness

5.      Inspect rear wheel scrapers for wear/damage (check wheel scraper video)

If pads need to be replaced (box #6):

6. Remove pin lock
7. Remove pins
8. Pull pads out
9. Spread pistons using tool
10. High temp brake grease on pad edges and piston contact point
11. Install pads and pins
12. Clip spring (front), pins have to slide through spring in rear
13. Install pin locks

If rotors needs to be replaced:

14. Remove caliper bolts
15. Attach rotor to S yellow hanger
16. Spread pistons using tool (see 9)
17. Swap rotors
18. Reinstall caliper

• Brake crew video below. Other userful videos are ABS diagnostic video and DCCD diagnostic video.

Suspension crew

Spares on the trailer wall. Check the Samsonas suspension  page and the balljoint video for more info.

• 1. Check lower strut mount bolts for tightness 

• 2. Check strut insert nut (24mm) under strut for tightness

• 3. Check strut spring rings for tightness

• 4. Remove SealSaver

• 5. Inspect spring for damage

• 6. Inspect insert for leak/damage

• 7. Reinstall SealSaver (front: logo facing you/rear: logo 90°)

• 8. Check top hat bolts for tightness

• 9. Inspect strut remote reservoir & hose for leak/damage

• 10. Front: Check control arm for damage

• 11. Front: Check tie rod + nut (19mm)

• 12. Front: Check balljoint (15+19mm)

• 13. Rear: Check lateral links + trailing arms bolts + damage

• 14. Check sway bars + endlinks

See the video below:

Tools organization

Check out the Tools page and the video below for the organization.:

We keep track of the tool location in this Google document: