Online Manual Jeep > Jeep Cherokee > Jeep Cherokee (XJ) > 1993 > BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES

1993 Jeep Cherokee

GENERAL INFORMATION

Brake Systems - Motorist Assurance Program

Standards For Automotive Repair

All Makes & Models CONTENTS

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

ACCELEROMETERS (G SENSOR OR LATERAL)

ACCUMULATORS

ANCHOR PINS

ANTI-LOCK BRAKE SYSTEMS

BACKING PLATES

BRAKE FLUID

BRAKE FRICTION MATERIAL

BRAKE PADS

BRAKE PEDALS

BRAKE SHOES

BRAKE SHOE HARDWARE

BRAKE STOPLIGHT SWITCHES

BULB SOCKETS

BULBS AND LEDS

CALIPER HARDWARE

CALIPERS

CONTROLLERS

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)

DISABLE SWITCHES

DRUMS

ELECTRICAL PUMPS AND MOTORS

ELECTRONIC CONTROLLERS

FLUID

FLUID LEVEL SENSOR SWITCHES

FOUR WHEEL DRIVE SWITCHES

FRICTION MATERIAL

G SENSORS

HOSES

HYDRAULIC MODULATORS

HYDRO-BOOSTERS

HYDRO-ELECTRIC BOOSTERS (POWERMASTER)

IGNITION DISABLE SWITCHES

LATERAL ACCELERATION SWITCHES

LEDS

LENSES

MASTER CYLINDERS

MODULATORS

MOTORS

PARKING BRAKE SWITCHES

PARKING BRAKE SYSTEMS

PADS

PEDAL TRAVEL SWITCHES

PEDALS

POWERMASTER

PUMPS

PRESSURE DIFFERENTIAL SWITCHES

PRESSURE SWITCHES

RELAYS

ROTORS

SELF-ADJUSTING SYSTEMS

SHOE HARDWARE

SHOES

SOCKETS

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

STEEL BRAKE LINES

STOPLIGHT SWITCHES

SWITCHES

TIRES

TOOTHED RINGS (TONE WHEEL)

VACUUM BOOSTERS

VACUUM HOSES

VALVES

WHEEL ATTACHING HARDWARE

WHEEL BEARINGS, RACES AND SEALS

WHEEL CYLINDERS

WIRING HARNESSES

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.

Our organizations mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper, manufacturer-recommended, maintenance. We encourage participating service and repair shops (including franchisees and dealers) to adopt:

  1. a Pledge of Assurance to their Customers and

  2. the Motorist Assurance Program Standards of Service.

All participating service providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.

These Standards of Service require that an inspection of the vehicles (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection communication standards are continually re-published. In addition to these, standards for Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication Standards as part of the inspection process and for communicating their findings to their customers.

The Motorist Assurance Program continues to work

cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.

To assure auto repair customers recourse if they were not

satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other non­profit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating the results of their inspection to their customers. To put some "teeth" in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the "mystery shopping" of outlets.

We welcome you to join us as we continue our outreach with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:

1444 I Street, NW Suite 700

Washington, DC 20005

Phone (202) 712-9042 Fax (202) 216-9646 January 1999

MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.

Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be "Required" or "Suggested". In addition, suggestions may be made to satisfy the requests expressed by the customer.

When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the customers best interest, and at his or her choice given the options available.

This section lists the various parts and conditions that indicate a required or suggested service or part replacement. Although this list is extensive, it is not fully inclusive. In addition to this list, a technician may make a suggestion. However, any suggestions must be based on substantial and informed experience, or the vehicle manufacturers recommended service interval and must be documented.

Some conditions indicate that service or part replacement is required because the part in question is no longer providing the function for which it is intended, does not meet a vehicle manufacturers design specification or is missing.

Example:

An exhaust pipe has corroded severely and has a hole in it through which exhaust gases are leaking. Replacement of the exhaust pipe in this case is required due to functional failure.

Example:

A brake rotor has been worn to the point where it measures

less than the vehicle manufacturers discard specifications.

Replacement of the rotor is required because it does not meet design specifications.

Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customers need, convenience or request. If a customers vehicle has one of these conditions, the procedure may be only to suggest service.

Example:

An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customers convenience in avoiding a future problem.

Example:

The customer desires improved ride and/or handling, but the vehicles shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customers wishes. In this case, replacement of the shocks or struts may not be sold as a requirement.

A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.

When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

The following reasons may be used for required and suggested services. These codes are shown in the "Code" column of the MAP Uniform Inspection & Communications Standards that follow:

Reasons to Require Repair or Replacement

A - Part no longer performs intended purpose

В - Part does not meet a design specification (regardless of

performance) С - Part is missing

NOTE: When a repair is required, the shop must refuse partial

service to the system in question, if the repair creates or continues an unsafe condition.

Reasons to Suggest Repair or Replacement

1 - Part is close to the end of its useful life (just above

discard specifications, or weak; failure likely to occur soon, etc.)

2 - To address a customer need, convenience, or request (to

stiffen ride, enhance performance, eliminate noise, etc.)

3 - To comply with maintenance recommended by the vehicles

Original Equipment Manufacturer (OEM)

4 - Technicians recommendation based on substantial and

informed experience

NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions

and make an informed decision about how to proceed.

BRAKES

SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER

VEHICLE OPERATION

Some states may have specifications that differ from OEM. Check your local/state regulations. Where state or local laws are stricter, they take precedence over these guidelines.

ACCELEROMETERS (G SENSOR OR LATERAL)

ACCELEROMETER INSPECTION

Condition Code Procedure

Broken A Require replacement.

Connector loose A .. Require repair or replacement.

Loose B . . Require repair or replacement.

Missing C Require replacement.

Out of position B Require re-positioning to

vehicle manufacturers

specifications.

Output signal incorrect . B Require replacement.

ACCUMULATORS

ACCUMULATOR INSPECTION

Condition Code Procedure

Leaking B Require replacement.

Missing C Require replacement.

Pre-charge incorrect .... B Require replacement.

ANCHOR PINS

See BACKING PLATES.

ANTI-LOCK BRAKE SYSTEMS

NOTE: Anti-lock brakes are an integral part of the brake system. It is essential that the anti-lock brakes function properly when brake service is performed.

Anti-lock brake systems are commonly referred to as "ABS" and will be referred to as "ABS" throughout these guidelines. Some ABS components also function as part of a traction control system (TCS).

WARNING: When diagnosing and servicing high pressure components, observe safety procedures and equipment requirements established by the vehicle manufacturer to reduce the possibility of serious personal injury.

NOTE: Intermittent electrical conditions are often caused by a loss of ground, poor connection, or water intrusion into the wiring harness.

NOTE: Electro-magnetic interference (EMI) may be caused by

incorrect installation of accessories or components. EMI can result in improper system operation.

BACKING PLATES

BACKING PLATE INSPECTION

Condition Code Procedure

Anchor pin bent B . . Require repair or replacement.

Anchor pin broken A Require replacement.

Anchor pin worn, affecting

structural integrity ... B Require replacement.

Backing plate bent B . . Require repair or replacement.

Backing plate broken .... A Require replacement.

Backing plate cracked ... B .. Require repair or replacement.
Corroded, affecting

structural integrity .... A Require replacement.

Loose B . . Require repair or replacement.

Missing C Require replacement.

Shoe lands worn A . . Require repair or replacement.

BRAKE FLUID

CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid in a system equipped with ABS.

DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light amber in color. DOT 5 brake fluid is violet in color. Correct fluid required for the brake system is stamped on the master cylinder cover.

BRAKE FLUID INSPECTION

Condition Code Procedure

Beyond service interval . 3 .. Suggest flushing and refilling

with correct fluid. Brake fluid type

incorrect B .. Require flushing and refilling

with correct fluid. Contaminated, for example, fluid other than brake

fluid present A or B ( 1) Require service.

Hydraulic component 3 .. Suggest flushing and refilling

overhaul or replacement with correct fluid.

Rubber master cylinder cover gasket distorted

and gummy A (2) Require replacement

of gasket.

(1) - If a fluid other than brake fluid is present in the brake system which DOES affect the rubber parts, the required service is to:

  1. Remove all components having rubber parts from the
    system.

  2. Flush lines with denatured alcohol or brake cleaner

  3. Repair or replace all components having rubber parts

  4. Flush and fill with correct brake fluid. (Code A)

If a fluid other than brake fluid is present in the brake

(2) -

system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct brake fluid. (Code B) This condition may indicate contaminated brake fluid.

BRAKE FRICTION MATERIAL

See FRICTION MATERIAL.

BRAKE PADS

See FRICTION MATERIAL.

BRAKE PEDALS

BRAKE PEDAL INSPECTION

Condition

Code

Procedure

Bent, affecting

performance A

Broken A

Pedal pad missing C

Pedal pad worn 1

Pivot bushings worn,

affecting performance ... A

Require repair or replacement.

Require repair or replacement.

Require replacement of pedal

pad.
Suggest replacement.

Require replacement of pivot

bushings.

BRAKE SHOES

See FRICTION MATERIAL.

BRAKE SHOE HARDWARE

See also SELF-ADJUSTING SYSTEMS BRAKE SHOE HARDWARE INSPECTION

Code

Condition

Broken A

Distorted A

Missing C

Surfaces rust-pitted .... 1
Worn, affecting

performance A

Procedure

Require replacement. Require replacement. Require replacement. Suggest replacement.

Require replacement.

BRAKE STOPLIGHT SWITCHES

BRAKE STOPLIGHT INSPECTION

Condition

Code

Procedure

Require repair or replacement.


В Require replacement.

A Require replacement.

A .. Require repair or replacement.

Bent

Broken

Connector broken

Connector (Weatherpack
type) leaking A

Connector melted Connector missing

Missing

Out of adjustment

Output signal incorrect
Terminal burned, affecting
performance

Terminal burned, not

affecting performance Terminal corroded, affecting performance ... Terminal corroded, not affecting performance Terminal loose, affecting

performance

Terminal loose, not affecting performance

Threads damaged

Threads stripped (threads
missing)

A (1) Require replacement.

С Require replacement.

С Require replacement.

В Require adjustment or

replacement.

В Require replacement.

A (2) Require repair

or replacement.

2 .. Suggest repair or replacement.

A .. Require repair or replacement.

2 .. Suggest repair or replacement.

В .. Require repair or replacement.

1 .. Suggest repair or replacement.

A .. Require repair or replacement.

A Require replacement.

  1. - Determine cause and correct prior to replacement of part.

  2. - Determine cause and correct prior to repair or replacement

of part.

BULB SOCKETS

BULB SOCKET INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Broken A

Bulb seized in socket ... A
Burned, affecting

performance A

Burned, not affecting
performance 2

Connector broken A

Connector missing C

Connector (Weatherpack

type) leaking A

Connector melted A

Corroded, affecting

performance A

Corroded, not affecting

performance 2

Leaking A

Melted A

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement. Require repair or replacement.

(1) Require repair

or replacement.

(1) Suggest repair

or replacement.

Require repair or replacement.
Require replacement.

Require repair or replacement.

(2) Require repair

or replacement.

Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

(2) Require replacement.

Shorted A

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

(1) - Determine cause and correct

replacement of socket.

(2) - Determine cause and correct

replacement of part.

Require repair or replacement. Require repair or replacement.

(2) Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement, prior to repair or prior to repair or

BULBS AND LEDS

NOTE: Copied from Electrical UIGs and modified. Does not include soldered-in components.

BULB AND LED INSPECTION

Missing C

Seized in socket A

Terminal broken A

Terminal burned, affecting
performance

Condition

Application incorrect
Base burned, affecting
performance

Base burned, not affecting
performance

Base corroded, affecting

performance

Base corroded, not

affecting performance . . Base loose, affecting

performance

Base loose, not affecting

performance

Burned out

Intermittent

Terminal burned, not affecting performance

Terminal corroded,

affecting performance .. Terminal corroded, not

affecting performance Terminal loose, affecting

performance

Code Procedure

В (1) Require replacement.

A (2) Require repair

or replacement.

2 (2) Suggest repair

or replacement.

A .. Require repair or replacement.

2 .. Suggest repair or replacement.

В .. Require repair or replacement.

1 .. Suggest repair or replacement.

A Require replacement.

A Require replacement.

Require replacement. Require repair or replacement. Require repair or replacement.

A (2) Require repair

or replacement.

2 (2) Suggest repair

or replacement.

A .. Require repair or replacement. 2 .. Suggest repair or replacement. В .. Require repair or replacement.

Terminal loose, not affecting performance

Suggest repair or replacement.

(1) - Application incorrect includes wrong bulb coating

or color.

(2) - Determine cause and correct prior to repair or

replacement of part.

CALIPER HARDWARE

CALIPER HARDWARE INSPECTION

Code

Condition

Bent A

Broken A

Corroded, affecting

performance A

Dust boots on slider pin

(bolt) missing C

Dust boots on slider pin

(bolt) torn A

Missing C

Shim bent A

Shim (OE standard)

missing C

Shim out of position .... B

Shim worn A

Slider pin (bolt) bent .. R

Slider pin (bolt)

rust-pitted A

Slider pin (bolt) worn ... A

Threads damaged A

Threads stripped (threads

missing) A

Worn, affecting

performance A

  1. - Removal is acceptable if

  2. - Aftermarket shims may be

Procedure

Require repair or replacement. Require repair or replacement.

Require repair or replacement. Require replacement of boots.

Require replacement of boots.

Require replacement.

(1) Require removal

or replacement.

(2) Require replacement.

(1) Require removal

or replacement.

(1) Require removal

or replacement.

Require replacement of slider

pin or bolt and lubricants.

Require replacement of slider pin or bolt and lubricants.

Require replacement of slider

pin or bolt and lubricants.

Require repair or replacement.

Require replacement. Require replacement.

shim is not OE.

suggested to reduce noise.

CALIPERS

You are not required to replace or rebuild calipers in axle sets. However, when replacing or rebuilding a caliper due to the conditions that follow, you may suggest servicing, rebuilding, or replacement of the other caliper (on the same axle) for improved performance and preventive maintenance (for example, the part is close to the end of its useful life, replacing the caliper may extend pad life, or contribute to more balanced braking).

CAUTION: When installing loaded calipers, it is required that

friction material be matched in axle sets for consistent braking characteristics.

CALIPER INSPECTION



Condition

Code

Bleeder port

damaged

A

Bleeder screw

broken off

in caliper

A

Bleeder screw

plugged

A

Bleeder screw

seized

. A

Casting corroded,

affecting structural

integrity A

Casting damaged, affecting

structural integrity ... A Dust boot around caliper

torn A

Leaking A

Mounting pin threads
damaged A

Mounting pin threads
stripped in caliper
bracket (threads
missing)

A

Mounting pin threads
stripped in steering
knuckle (threads
missing)

Mounting pin threads
stripped (threads
missing)

Parking brake cable
support, lever, or return
spring bent A

Parking brake cable
support, lever, or return
spring broken A

Parking brake mechanism in caliper inoperative .... A

Piston corroded (pitted
or peeling chrome
plating) B

Piston damaged, affecting
performance

Piston damaged, not affecting performance

Piston finish worn off

Procedure

Require repair or replacement of caliper.

(1) Require repair or

replacement of caliper.

(1) Require repair or

replacement of bleeder screw.

(2) Require replacement

of caliper.

Require replacement. Require replacement.

Require replacement of dust

boot. Require repair or replacement.

Require repair or replacement

of component with damaged

threads.

Require repair or replacement of caliper bracket.

Require repair or replacement of steering knuckle.

Require repair or replacement

of component with stripped

threads.

Require replacement of parts.

Require replacement of parts. Require repair or replacement.

Require replacement of piston

and rebuilding or replacement

of caliper.

Require replacement of piston

and rebuilding or replacement

of caliper.

No service suggested or

required.

Require replacement of piston and rebuilding or replacement

Piston sticking A

Slide mechanism
sticking A

of caliper.

Require rebuilding or

replacement of caliper.

Require repair or replacement of slide mechanism.

  1. - Only required if the hydraulic system must be opened.

  2. - Seized is defined as a bleeder screw that cannot be

removed after a practical attempt at removing. Only required if the hydraulic system must be opened.

CONTROLLERS

See ELECTRONIC CONTROLLERS.

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)

DIGITAL RATIO AXLE CONTROLLER AND BUFFER INSPECTION

Code

Condition

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Missing C

Output signal incorrect . B
Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance ... A Terminal corroded, not

affecting performance . . 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Procedure Require repair or replacement.

Require repair or replacement.

(1) Require replacement.

Require replacement.

Require replacement.

Require repair or replacement.

(2) Require repair

or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement.

  1. - Determine cause and correct prior to replacement of part.

  2. - Determine cause and correct prior to repair or

replacement of part.

DISABLE SWITCHES

See SWITCHES.

DRUMS

Determine the need to recondition based upon individual drum conditions that follow. Friction material replacement does not require drum reconditioning unless other justifications exist. DO NOT recondition new drums unless they are being pressed or bolted onto an existing hub. It is not necessary to replace drums in axle sets. However, when replacing or reconditioning a drum due to the conditions that follow, you may suggest reconditioning of the other drum on the

same axle to eliminate uneven braking behavior. Always wash drums after servicing or before installing.

DRUM INSPECTION

Condition

Balance weight missing

Bell-mouthed, affecting
performance

Cooling fin broken

Cracked

Drum diameter is greater
than OEM "machine to"
specifications but less
than "discard at"
specifications, and the
drum does not require
reconditioning

Drum diameter will exceed
OEM "machine to"
specifications after
required
reconditioning

Hard-spotted

Measured diameter is
greater than OEM discard
specifications

Out-of-round (runout), affecting performance ..

Out-of-round (runout),
exceeding manufacturer s
specifications

Scored

Surface threaded due to improper machining

Tapered, affecting
performance

Code

Procedure

No service suggested or required.

A Require reconditioning or

replacement.

No service suggested or

required.
В Require replacement.

(1) Suggest replacement.

В (2) Require replacement.

2 Suggest reconditioning or

replacement.

В Require replacement.

A Require reconditioning or

replacement.

В Require reconditioning or

replacement.

В Require reconditioning or

replacement.

В Require reconditioning or

replacement.

A

Require reconditioning or replacement.

(1) - Only applies to vehicles for which OEM "machine to"

specifications exist. If OEM does not supply "machine to" specifications, the drum may be worn to discard specifications.

(2) - If OEM does not supply "machine to" specifications, you

may machine to discard specifications.

ELECTRICAL PUMPS AND MOTORS

Copied fuel pump conditions from engine UIGs & deleted pulsator from leaking conditions.

ELECTRICAL PUMP AND MOTOR INSPECTION

Condition

Code

Procedure

Attaching hardware
broken

С

Attaching hardware
missing

Attaching hardware not

functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Contaminated A

Inoperative A

Leaking externally A

Leaking internally A

Noisy 2

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2
Terminal corroded,

affecting performance .. . A
Terminal corroded, not

affecting performance .. 2
Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped (threads

missing) A

Wire lead conductors

exposed B

Wire lead corroded A

Wire lead open A

Wire lead shorted A

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

(1) Require repair

or replacement.

Require replacement.

(2) Require replacement.

(3) Require repair

or replacement.

Require repair or replacement.

Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

(1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement. Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement

of part.

(2) - Determine source of contamination. Require repair or

replacement.

(3) - Inoperative includes intermittent operation or out of OEM

specifications.

ELECTRONIC CONTROLLERS

ELECTRONIC CONTROLLER INSPECTION

Condition

Application incorrect
Attaching hardware
missing

Code Procedure

В Require replacement.

С Require replacement of

Attaching hardware threads
damaged A

Attaching hardware threads
stripped (threads
missing) A

Code set (if
applicable) A

Connector broken A

Connector melted A

Connector missing A

Contaminated A

Inoperative B

Leaking A

Missing C

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped (threads

missing) A

Wire lead conductors

exposed B

Wire lead corroded A

Wire lead open A

Wire lead shorted A

hardware.

Require repair or replacement of hardware.

Require repair or replacement of hardware.

(1) Further inspection

required. Require repair or replacement.

(2) Require repair or

replacement.

Require repair.

Require repair or replacement.

Require repair or replacement.

(3) Further inspection required.

Require repair or replacement.

Require replacement.

Require repair or replacement.

(2) Require repair or

replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement. Require repair or replacement.

(1) - Refer to manufacturers diagnostic trouble code procedure

and require repair or replacement of affected component(s).

(2) - Determine cause and correct prior to repair or replacement

of part.

(3) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable. Check for accepted cleaning procedure.

FLUID

See BRAKE FLUID.

FLUID LEVEL SENSOR SWITCHES

See SWITCHES.

FOUR WHEEL DRIVE SWITCHES

See SWITCHES.

FRICTION MATERIAL

NOTE: Original Equipment Manufacturer (OEM) specifications designate replacement at different thicknesses.

CAUTION: It is required that friction material be matched in axle sets for consistent braking characteristics.

FRICTION MATERIAL INSPECTION

Code

A В В

Condition

Contaminated, for example,
fluid that leaked from
caliper, wheel cylinder,
or axle seal

Cracked through

Flaking or chunking

Glazed (shiny)

Grooves or ridges

Permanently attached

hardware bent

Permanently attached

hardware broken

Permanently attached

hardware loose

Permanently attached

hardware missing

Permanently attached

hardware seized

Rivets loose

Separating from backing Shoe table or web bent Shoe table or web

cracked

Shoe table or web worn,

affecting performance
Surface cracking

Tapered wear

Thickness of one pad is
greater than opposite pad
in the same caliper
(uneven wear)

Wear indicator device
(electronic) contacts
rotor

Wear indicator device (mechanical) bent

Wear indicator device (mechanical) broken

Procedure

(1) Require replacement.

Require replacement.

Require replacement.

No service suggested or

required.

(2) No service suggested or required.

A Require replacement.

A Require replacement.

A Require replacement.

С Require replacement.

A .. Require repair or replacement.

В Require replacement.

В Require replacement.

В Require replacement.

A Require replacement.

A Require replacement.

No service suggested or

required. Further inspection may be necessary to determine

cause.
В (3) Suggest replacement.

(4) Replacement of friction

material not suggested or

required. Further inspection

required. See CALIPERS

and CALIPER HARDWARE.

(5) Require replacement of appropriate parts.

(6) Further inspection required.

(6) Further inspection required.

Wear indicator device
(mechanical) contacts
rotor

Worn close to minimum

specifications 1

Worn to, or below minimum

specifications B

(6) Further inspection required.

(7) Suggest replacement. Require replacement.

(1) - Identify and repair cause of contamination prior to

replacing friction material.

(2) - When reconditioning or replacing drums or rotors,

replacement of friction material may be suggested depending on the severity of the grooves or ridges.

(3) - Some vehicles use pads that are tapered by design. Refer

to specific vehicle application. If not normal, require replacement of pads and correction of cause.

(4) - Uneven pad thickness is normal on some vehicles. Refer to

specific vehicle applications.

(5) - The pad wear indicator light may come on due to other

electrical problems.

(6) - Explain to the customer that the purpose of the wear

indicator is to alert him or her to check for friction wear. Wear indicators may be bent or broken. Therefore, the friction material must be measured. The need for friction material replacement is determined based upon the conditions stated in this section. Periodic inspection is suggested.

(7) - When the part appears to be close to the end of its useful

life, replacement may be suggested.

G SENSORS

See ACCELEROMETERS.

HOSES

HOSE INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Blistered B

Fitting threads damaged . A Fitting threads stripped

(threads missing) A

Incorrectly secured B

Inner fabric

(webbing) cut B

Leaking A

Missing C

Outer covering is cracked

to the extent that

inner fabric of hose

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require replacement.

Require repair or replacement.

Require replacement.

Require repair.

Require replacement.

Require replacement.

Require replacement.

is visible B Require replacement.

Restricted A Require replacement.

Routed incorrectly B Require repair.

HYDRAULIC MODULATORS

NOTE: Many modulators can only be replaced as complete assemblies. Whenever possible, replace the failed component part. If replacement of the failed part is not possible, then replace the modulator assembly.

HYDRAULIC MODULATOR INSPECTION

Condition

Code

Procedure

Attaching hardware

broken A

Attaching hardware

missing C

Attaching hardware not

functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Disabled A

Electrical failure A

External leak A

Housing cracked B

Inoperative (2) A

Internal leak A

Missing C

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2
Terminal corroded,

affecting performance .. . A
Terminal corroded, not

affecting performance .. 2
Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped (threads

missing) A

Valve stuck A

Wire lead burned A

Wire lead conductors

exposed B

Wire lead open A

Wire lead shorted A

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

(1) Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.
Require replacement.

1) Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement. Require repair or replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement.

  1. - Determine cause and correct prior to replacement of part.

  2. - Inoperative includes intermittent operation or out of OEM

specification.

HYDRO-BOOSTERS

NOTE: Hydro-boosters and hydro-electric boosters are combined.

HYDRO-BOOSTER INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A ( 1) Require replacement.

Connector missing C Require replacement.

Does not apply assist, or

inadequate assist A .. Require repair or replacement.

Leaking B . . Require repair or replacement.

Leaks fluid at fitting . . B Require tightening or

replacement.

Leaks fluid at unit B .. Require repair or replacement.

Leaks fluid from pressure

hose (s) B . Require replacement of hose(s) .

Leaks fluid into passenger

compartment B . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Threads stripped (threads

missing) A Require replacement.

(1) - Determine cause and correct prior to replacement of part. HYDRO-ELECTRIC BOOSTERS (POWERMASTER)

See HYDRO-BOOSTERS.

IGNITION DISABLE SWITCHES

See SWITCHES.

LATERAL ACCELERATION SWITCHES

See ACCELEROMETERS.

LEDS

See BULBS AND LEDS.

LENSES

LENSE INSPECTION

Condition

Code

Procedure

Application incorrect ... A Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Broken, affecting

performance A Require replacement.

Broken, not affecting

performance No service suggested or

required.

Cracked A Require replacement.

Discolored A Require replacement.

Leaking A . . Require repair or replacement.

Melted, affecting

performance A Require replacement.

Melted, not affecting

performance 2 Suggest replacement.

Missing C Require replacement.

MASTER CYLINDERS

MASTER CYLINDER INSPECTION

Condition

Code

Procedure

Brake fluid leaking from
rear of master cylinder
bore B

Brake pedal drops
intermittently A

Fluid level low

Internal valve failure .. . A Master cylinder leaking

brake fluid internally . A Piston does not return .. . A

Ports plugged A

Rubber master cylinder
cover gasket distorted
and gummy A

Require repair or replacement.

(1) Require repair or

replacement.

(2) Further inspection

required. Require repair or replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement.

(3) Require replacement of the

gasket.

(1) - This condition may be normal on some vehicles equipped with

anti-lock brakes.

(2) - Refer to OEM procedures for adjusting low fluid level.

Inspect for brake hydraulic system leaks and friction material wear.

(3) - This condition may indicate contaminated brake fluid.

See BRAKE FLUID.

MODULATORS

See HYDRAULIC MODULATORS.

MOTORS

See ELECTRICAL PUMPS AND MOTORS.

PARKING BRAKE SWITCHES

See SWITCHES.

PARKING BRAKE SYSTEMS

NOTE: The parking brake is an integral part of the brake

system. It is important that the parking brake function properly when brake service is performed.

PARKING BRAKE SYSTEM INSPECTION

Code

Condition

Attaching hardware
broken

A

Attaching hardware
missing

Attaching hardware not
functioning A

Cable improperly

adjusted B

Cable or individual

wires in the cable

are broken A

Cable sticking A

Cable stuck inside conduit
and cannot be lubricated
so that parking brake
functions properly A

A

Inoperative (1)

Parking brake
parts bent B

Parking brake
parts broken A

Parking brake parts

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

. .. Require cable adjustment.

Require replacement of cable

assembly. Require cable lubrication.

Require replacement of cable

assembly.

Require replacement of

inoperative parts.

Require repair or replacement of bent parts.

Require replacement of broken

parts.

missing C . . Require replacement of missing

parts.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Inoperative includes intermittent operation. PADS

See FRICTION MATERIAL.

PEDAL TRAVEL SWITCHES

See SWITCHES.

PEDALS

See BRAKE PEDALS.

POWERMASTER

See HYDRO-BOOSTERS.

PUMPS

See ELECTRICAL PUMPS AND MOTORS.

PRESSURE DIFFERENTIAL SWITCHES

See SWITCHES.

PRESSURE SWITCHES

See SWITCHES.

RELAYS

NOTE: Copied from Electrical UIGs

RELAY INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Housing broken A Require replacement.

Housing cracked 2 Suggest replacement.

Inoperative (1) A Require replacement.

Missing C Require replacement.

Terminal broken A . . Require repair or replacement.

Terminal burned,

affecting performance . . A (2) Require repair or

replacement.

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement.

(1) - Inoperative includes intermittent operation or out of OEM

specification.

(2) - Determine cause and correct prior to repair or

replacement of part.

ROTORS

Determine the need to recondition based upon individual rotor conditions that follow. Friction material replacement does not require rotor reconditioning unless other justifications exist. DO NOT recondition new rotors unless they are being pressed or bolted onto an existing hub. It is not necessary to replace rotors in axle sets. However, when replacing or reconditioning a rotor due to the conditions that follow, you may suggest reconditioning of the other rotor on the same axle to eliminate uneven braking behavior.

Determine the need to replace based upon the individual rotor conditions that follow. Reconditioning is defined as machining and block sanding, or block sanding only. Block sanding is defined as using 120-150 grit sandpaper with moderate to heavy force for 60 seconds per side. Always wash rotors after servicing or before installing.

ROTOR INSPECTION

Code

Condition

Corrosion affecting structural integrity

Cracked

Hard spots

Procedure

A (1) Require replacement.

В Require replacement.

2 Suggest reconditioning or

replacement of rotor according to OEM specifications.

Lateral runout (wobble)
exceeds OEM
specifications B

Require re-indexing,

reconditioning, or replacement according to specifications.

Require replacement.

Measured thickness is less
than OEM discard
specifications B

(2) Suggest replacement.

Rotor thickness is less
than OEM "machine to"
specifications but thicker
than "discard at"
specifications, and the
rotor does not require
reconditioning 1

Rotor thickness will be less than OEM "machine to" specifications after required

reconditioning B (3) Require replacement.

Surface is rust-pitted . . B Require reconditioning or

replacement of rotor according to OEM specifications.

Surface is scored B ... (4) Require reconditioning or

replacement of rotor according to OEM specifications. Thickness variation (parallelism) exceeds OEM

specifications B Require reconditioning or

replacement of rotor according to OEM specifications.

(1) - Examples of severe corrosion are: composite plate

separated from friction surfaces and cooling fins cracked or missing.

(2) - Only applies to vehicles for which OEM "machine to"

specifications exist. If OEM does not supply "machine to" specifications, the rotor may be worn to discard specifications.

(3) - If OEM does not supply "machine to" specifications,

you may machine to discard specifications.

(4) - Scoring is defined as grooves or ridges in the friction

contact surface. Some vehicle manufacturers require machining when scoring exceeds their allowable specifications.

SELF-ADJUSTING SYSTEMS

SELF-ADJUSTING SYSTEM INSPECTION

Condition Code Procedure

Bent A ... Require repair or replacement

of bent part.

Broken A ... Require repair or replacement

of broken part.

Inoperative A (1) Require repair or

replacement of inoperative

parts.

Missing C Require replacement of

missing part.
Star wheel does not turn
freely A .. Require repair or replacement.

(1) - Inoperative includes intermittent operation. SHOE HARDWARE

See BRAKE SHOE HARDWARE.

SHOES

See FRICTION MATERIAL.

SOCKETS

See BULB SOCKETS.

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

NOTE: Copied Vehicle Speed Sensors from Engine UIGs & added Air Gap incorrect, loose, and wire lead misrouted. For "contaminated" removed coolant & fuel examples from note.

SPEED SENSOR INSPECTION

Condition Code

Air gap incorrect B

Attaching hardware
missing C

Attaching hardware

threads damaged A

Attaching hardware threads stripped

(threads missing) A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Contaminated A

Inoperative B

Lead routing incorrect .. R

Leaking A

Loose A

Missing C

Resistance out of

specification B

Sensor housing cracked . . 2

Terminal broken A

Terminal burned,

affecting performance .. A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose,

affecting performance . . R Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped

(threads missing) A

Wire lead conductors

exposed B

Wire lead corroded A

Wire lead misrouted B

Procedure

1) Require adjustment or replacement.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

(2) Require repair or

replacement.

Require replacement.

(3) Require repair or

replacement.

(4) Require repair or

replacement. Further

inspection required.

. . Require rerouting according

to vehicle manufacturers

specifications.

Require repair or replacement.

Require repair or replacement.

Require replacement.

Require repair or replacement.

Suggest replacement.

Require repair or replacement.

(2) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require re-routing according to

vehicle manufacturers

Wire lead open A

Wire lead shorted A

specifications.

Require repair or replacement. Require repair or replacement.

(1) - If a sensor is not adjustable, further inspection is

required to identify and correct cause.

(2) - Determine cause and correct prior to repair or

replacement of part.

(3) - Determine source of contamination, such as metal

particles or water. Require repair or replacement.

(4) - Inoperative includes intermittent operation or out of OEM

specification. Some components may be serviceable; check for accepted cleaning procedure.

STEEL BRAKE LINES

STEEL BRAKE LINE INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Corroded, affecting

structural integrity ... A
Fitting incorrect (for

example, compression

fitting) B

Flare type incorrect .... B

Leaking A

Line material incorrect

(copper, etc.).) В

Restricted A

Routed incorrectly B

Rust-pitted 1

Threads damaged A

Threads stripped

(threads missing) A

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require replacement.

Require replacement.

Require repair or replacement. Require repair or replacement.

Require replacement.

Require replacement.

Require routing correction.

Suggest replacement.

Require repair or replacement.

Require replacement.

STOPLIGHT SWITCHES

See BRAKE STOPLIGHT SWITCHES.

SWITCHES

NOTE: Copied from Electrical UIGs & added "float saturated" from old fluid level sensor switches.

STEEL BRAKE LINE INSPECTION

Code

Condition

Attaching hardware
broken

Procedure

A ... Require repair or replacement

of hardware.

Attaching hardware
missing

Attaching hardware not
functioning A

Binding, affecting
performance

2 A

A

Binding, not affecting
performance

Broken

Burned, affecting
performance

Burned, not affecting
performance

Cracked, affecting

performance A

Cracked, not affecting

performance 1

Float saturated A

Leaking A

Malfunctioning A

Melted, affecting

performance A

2

Melted, not affecting
performance

Missing C

Out of adjustment B

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance Terminal corroded,

A

affecting performance .. Terminal corroded, not

affecting performance Terminal loose, affecting

performance

Terminal loose, not

1

A 1

affecting performance

Wont return

Worn

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

(1) Require repair or replacement.

(1) Suggest repair or replacement.

Require repair or replacement.

Suggest repair or replacement.
Require replacement.

Require repair or replacement.

(2) Require repair or

replacement.

(1) Require repair or replacement.

(1) Suggest repair or

replacement.
Require replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement.

Require repair or replacement.

Suggest replacement.

(1) - Determine cause and correct prior to repair or

replacement of part.

(2) - Includes inoperative, intermittent operation, or failure to

perform all functions.

TIRES

Consult the vehicle owners manual or vehicle placard for correct size, speed ratings, and inflation pressure of the original tires.

TIRE INSPECTION

Condition Code Procedure

Tire diameter incorrect,

affecting ABS or TCS ... A Require replacement.

Tire pressure incorrect,

affecting ABS or TCS ... A .. Require repair or replacement. Tire size incorrect,

affecting ABS or TCS ... A Require replacement.

TOOTHED RINGS (TONE WHEEL)

NOTE: Copied from Drivetrain UIGs.

If the toothed ring requires replacement and cannot be replaced as a separate component, replace the assembly of which the ring is a part.

TOOTHED RING INSPECTION

Condition Code Procedure

Alignment incorrect B Require repair or

replacement.

Bent B Require replacement.

Contaminated, affecting

performance A Require repair. Identify

and correct cause.

Cracked B Require replacement.

Loose A Require replacement

of worn parts.

Missing C Require replacement.

Number of teeth

incorrect B Require replacement.

Teeth broken A Require replacement.

Teeth damaged, affecting

performance A Require replacement.

VACUUM BOOSTERS

VACUUM BOOSTER INSPECTION

Condition Code Procedure

Applies too much assist

(oversensitive) A Require replacement.

Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware. Auxiliary vacuum pump

inoperative A (1) Require repair or

replacement.
Check valve grommet
deteriorated, affecting
performance A . . Require replacement of grommet.

1

A

Check valve grommet deteriorated, not affecting performance

Check valve inoperative

Check valve leaking A

Check valve missing C

Check valve noisy 2

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Leaking A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Threads damaged A

Threads stripped (threads

missing) A

Vacuum hose filter

leaking A

Vacuum hose filter

restricted A

Wire lead burned A

Wire lead conductors

exposed B

Wire lead open A

Wire lead shorted A

Suggest replacement of grommet.

(2) Require repair or

replacement.

. . Require replacement of check

valve.

Require replacement of check

valve.

Suggest replacement.

Require repair or replacement.

Require repair or replacement.

(3) Require replacement.

Require replacement.

Require replacement.

(3) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require replacement of filter.

Require replacement of filter. Require repair or replacement.

Require repair or replacement. Require repair or replacement. Require repair or replacement.

(1) - Inoperative includes intermittent operation or out of

OEM specification.

  1. - Inoperative includes intermittent operation.

  2. - Determine cause and correct prior to replacement of part.

VACUUM HOSES

See HOSES.

VALVES

VALVE INSPECTION

Code

Condition

Attaching hardware
broken

Attaching hardware
missing

Procedure

A ... Require repair or replacement

of hardware.

С Require replacement of

hardware. Attaching hardware

not functioning A ... Require repair or replacement

of hardware.

Leaking B . . Require repair or replacement.

Linkage bent (rear

load valves) A ... Require repair or replacement

of linkage. Linkage broken (rear

load valves) A ... Require repair or replacement

of linkage. Linkage disconnected

(rear load valves) C ... Require repair or replacement

of linkage. Pressure out of

specification B Require adjustment. If not

possible, require replacement.

Seized A Require replacement.

Sticking A . . Require repair or replacement.

Terminal burned,

affecting performance . . A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Wire lead burned A .. Require repair or replacement.

Wire lead conductors

exposed B .. Require repair or replacement.

Wire lead open A . . Require repair or replacement.

Wire lead shorted A .. Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.

WHEEL ATTACHING HARDWARE

For conditions noted below, also check condition of wheel stud holes.

CAUTION: Proper lug nut torque is essential. Follow manufacturers torque specifications and tightening sequence. DO NOT lubricate threads unless specified by the vehicle manufacturer.

WHEEL ATTACHING HARDWARE INSPECTION

Condition Code Procedure

Bent A Require replacement.

Broken A ( 1) Require replacement.

Loose B ... Require repair or replacement

of affected component.

Lug nut flats rounded ... A Require replacement of nut.

Lug nut installed

backward B Require repair.

Lug nut mating surface

dished A Require replacement of nut.

Lug nut mating type

incorrect B Require replacement of nut.

Lug nut seized A Require replacement of nut

and/or stud.

Stud incorrect B .... Require replacement of stud.

Threads damaged A ... Require repair or replacement

of component with damaged threads. Threads stripped (threads

missing) A Require replacement of

component with stripped threads.

(1) - Some manufacturers require replacement of all studs on

any wheel if two or more studs or nuts on the same wheel are broken or missing.

WHEEL BEARINGS, RACES AND SEALS

NOTE: Grease seal replacement is required if seal is removed. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions that follow.

WHEEL BEARINGS, RACES AND SEALS INSPECTION

Condition

Code

Procedure

Axle seal on drive axle
leaking A

Bearing end-play exceeds
specifications B

Bearing rollers, balls or
races are worn, pitted, or
feel rough when rotated as
an assembly B

Seal leaking A

Spindle worn B

Require replacement of seal and

inspection of axle, bearing,

housing, and vent tube.

Require adjustment of bearing,

if possible. If proper

adjustment cannot be obtained,

require replacement of bearing

assembly.

Require replacement of bearing

assembly.

(1) Require replacement of

seal and inspection of bearings.

Require replacement of spindle

and bearings.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.

WHEEL CYLINDERS

You are not required to replace or rebuild wheel cylinders in axle sets. However, when rebuilding or replacing a wheel cylinder due

to the conditions that follow, you may suggest rebuilding or replacement of the other wheel cylinder (on the same axle) for preventive maintenance, for example, the part is close to the end of its useful life.

Determine the need to rebuild or replace based upon the individual wheel cylinder conditions that follow.

WHEEL CYLINDER INSPECTION

Code

Condition

Attaching hardware bent

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity ... A

Attaching hardware

loose A

Attaching hardware

missing C

Attaching hardware not
functioning A

Bleeder port damaged (if
non-repairable) A

Bleeder screw broken off
in wheel cylinder (if non-
repairable) A

Bleeder screw plugged ... A

Bleeder screw seized .... A

Bore corroded (pitted) . . R

Bore grooved A

Bore oversized B

Dust boot missing C

Dust boot torn A

Leaking A

Piston corroded, affecting
performance B

Piston finish worn off .. R

Piston stuck in bore .... A

Loose B

Threads damaged A

Threads stripped (threads

missing) A

Procedure

Require replacement of bent

parts.

Require repair or replacement of hardware.

Require replacement of corroded

parts.

Require repair or replacement.

Require replacement of hardware.

Require repair or replacement of hardware.

Require replacement.

(1) Require replacement.

(1) Require repair or

replacement of bleeder screw.

(2) Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement of dust

boot.

(3) Require replacement of dust

boot.

.... (4) Require rebuilding or

replacement.

Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Require replacement of wheel

cylinder.

Require repair or replacement. Require repair or replacement.

Require replacement.

  1. - Only required if the hydraulic system must be opened.

  2. - Seized is defined as bleeder screw that cannot be removed

after a practical attempt at removing. Only required if the hydraulic system must be opened.

  1. - Inspect for conditions related to wheel cylinder.

  2. - Leaking is defined as a drop or more. Dampness is normal.

WIRING HARNESSES

NOTE: Copied from Electrical UIGs.

WIRING HARNESS INSPECTION

Condition Code Procedure

Application incorrect ... B .. Require repair or replacement. Attaching hardware

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A ... Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Insulation damaged,

conductors exposed A .. Require repair or replacement.

Insulation damaged,

conductors not exposed . 1 Suggest replacement.

Open A . . Require repair or replacement.

Protective shield

(conduit) melted 2 (1) Suggest repair or

replacement. Protective shield

(conduit) missing 2 .. Suggest repair or replacement.

Resistance (voltage drop)

out of specification ... A .. Require repair or replacement.

Routed incorrectly B Require repair.

Secured incorrectly B Require repair.

Shorted A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance .. A .. Require repair or replacement. Terminal corroded, not

affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting

performance B . . Require repair or replacement.

Terminal loose, not

affecting performance .. 1 .. Suggest repair or replacement. Voltage drop out of

specification A . . Require repair or replacement.

(1) - Determine cause and correct prior to repair or replacement of part.