1993 Jeep Cherokee

GENERAL INFORMATION

Steering, Suspension, Wheel Alignment, Wheels and Tires

Motorist Assurance Program

Standards For Automotive Repair

All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

Motorist Assurance Program (MAP)

OVERVIEW

OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

Steering and Suspension

TIE ROD ENDS (INNER AND OUTER)

TRACK BARS

TRAILING ARMS

WHEEL BEARINGS, RACES AND SEALS

Wheel Alignment WHEEL ALIGNMENT Wheels and Tires

TIRES

VALVE STEMS

WHEEL ATTACHMENT HARDWARE

WHEELS (RIMS)

MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW

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 organization’s 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 vehicle’s (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 non-

profit 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 & 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 customer’s 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 manufacturer’s 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 manufacturer’s 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 manufacturer’s 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 customer’s need, convenience or request. If a customer’s 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 customer’s convenience in avoiding a future problem.

Example:

The customer desires improved ride and/or handling, but the vehicle’s shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customer’s 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

Ð’ - 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 vehicle’s

Original Equipment Manufacturer (OEM)

4 - Technician’s 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.

STEERING AND SUSPENSION

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER VEHICLE

OPERATION

Steering and suspension are complex systems made up of a variety of interdependent components. For proper vehicle handling, ride, and tire wear, a thorough inspection is required whenever suspension work is being performed.

Conditions listed assume that the problem has been isolated to the specific component by proper testing procedures.

NOTE: When replacing steering and/or suspension components which may affect an alignment angle, you are required to check and adjust alignment as needed. Refer to the OEM specifications.

CAUTION: DO NOT use ride height altering or load compensating

components, such as variable rate springs and coil over shocks, on vehicles with height or load sensing proportioning valve-equipped braking systems, unless these components are original equipment.

AIR RIDE SUSPENSION

NOTE: Depending on the air suspension design, there are some

aftermarket products available to eliminate the air ride suspension on certain vehicles. If the system has been eliminated with one of these products, then no service is suggested or required.

AIR RIDE SUSPENSION - AIR SHOCKS AND AIR STRUTS

NOTE: This section covers the air spring portion of the air shock or strut. For damping portion of shock or strut conditions and procedures, refer to the SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES section.

AIR RIDE SUSPENSION - AIR SHOCK AND AIR STRUT INSPECTION
Condition Code Procedure

Inner fabric of air bag

damaged A Require replacement.

Leaking A . . Require repair or replacement.

Outer covering of air bag

is cracked to the extent

that inner fabric of air

bag is visible 1 Suggest replacement.

AIR RIDE SUSPENSION - AIR SPRING VALVES

AIR RIDE SUSPENSION - AIR SPRING VALVE INSPECTION

Condition Code Procedure

Attaching hardware

incorrect A

Attaching hardware

loose A

Attaching hardware

missing C

Attaching hardware

threads damaged A

Attaching hardware threads stripped

(threads missing) A

Blocked A

Connector bent A

Connector broken A

Connector loose A

Inoperative A

Leaking A

Restricted A

Require replacement of incorrect part.

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Require replacement of part

with stripped threads.

Require 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.

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Collar cracked A

End cap cracked A

Inner fabric of bag

damaged A

Leaking A

Outer covering of air bag is cracked to the extent that inner fabric of air

bag is visible 1

Piston cracked A

Require replacement of broken

part.

Require replacement of incorrect part.

Require repair or replacement of loose part.

Require replacement of missing

part

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

Require replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Suggest replacement. Require replacement.

AIR RIDE SUSPENSION - COMPRESSORS

AIR RIDE SUSPENSION - COMPRESSOR INSPECTION

... Require replacement of part with stripped threads. Require repair or replacement.

A Require replacement.

A .. Require repair or replacement.

A (1) Further inspection

required.

Ð’ (2) Further inspection

required.

Inoperative A Require replacement.

Leaking A . . Require repair or replacement.

Missing C Require replacement.

(1) - If failure to build pressure is traced to the

compressor, require replacement.

(2) - If excessive run time is traced to the compressor,

require replacement.

Condition Code

Attaching hardware bent . B

Attaching hardware
broken A

Attaching hardware
loose

Attaching hardware
missing

Attaching hardware
threads damaged A

Attaching hardware threads stripped (threads missing)

Procedure

Require repair or replacement of bent part.

Require replacement of broken

part.

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Condition

Attaching hardware bent

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity

Attaching hardware
loose

Attaching hardware
missing

Attaching hardware

Code Ð’

A A

Procedure

Require repair or replacement of bent part.

Require replacement of broken

part.

Require replacement of corroded part.

Require repair or replacement of loose part.

Require replacement of missing

part.

threads damaged A

Attaching hardware threads stripped (threads missing)

Dust boot missing 2

Dust boot split 2

Dust boot torn 2

Housing cracked A

Lead routing incorrect .. R

Loose

Missing C

Output signal incorrect . A
Wire lead damaged A

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

(1) Suggest replacement.

(1) Suggest replacement.

(1) Suggest replacement.

Require replacement.

Require rerouting according to

vehicle manufacturer’s

specifications.

Require adjustment to vehicle

manufacturer’s specifications.

Require replacement.

Require repair or replacement. Require repair or replacement.

Condition

Code

Procedure

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Housing cracked 2

Inoperative A

Missing C

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Require replacement of part

with stripped threads.

Suggest repair or replacement.

Require replacement.

Require replacement.

Condition

Code

Procedure

AIR RIDE SUSPENSION - SWITCH (ON/OFF) INSPECTION

Condition Code Procedure

Broken A Require replacement.

Missing C Require replacement.

Output signal incorrect . A Require replacement.

AIR RIDE SUSPENSION - TORSION SPRINGS (COUNTER BALANCING)

AIR RIDE SUSPENSION - TORSION SPRING (COUNTER BALANCING) INSPECTION
Condition Code Procedure

Attaching hardware bent . B ... Require repair or replacement

of bent part. Attaching hardware

broken A ... Require replacement of broken

part. Attaching hardware

incorrect A Require replacement of

incorrect part. Attaching hardware

loose A ... Require repair or replacement

of loose part. Attaching hardware

missing C . . Require replacement of missing

part. Attaching hardware

threads damaged A ... Require repair or replacement

of part with damaged threads. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads.

Broken A Require replacement.

Missing C Require replacement.

AIR RIDE SUSPENSION - TUBING

AIR RIDE SUSPENSION - TUBING INSPECTION

Condition Code Procedure

Attaching hardware

incorrect A Require replacement of

incorrect part. Attaching hardware

loose A ... Require repair or replacement

of loose part. Attaching hardware

missing C . . Require replacement of missing

part.

Blocked A . . Require repair or replacement.

Fitting incorrect B Require replacement.

Leaking A . . Require repair or replacement.

Line type incorrect B Require replacement.

Missing C Require replacement.

Restricted A . . Require repair or replacement.

Routed incorrectly B Require routing correction.

AIR RIDE SUSPENSION - WARNING LAMPS

AIR RIDE SUSPENSION - WARNING LAMP INSPECTION

Condition

Code

Procedure

Code

Condition

Connector bent A

Connector broken A

Connector loose A

Damaged (cut, burned, or

chafed) A

Excessive resistance .... B

Fuse blown A

Fusible link blown A

Open A

Poor ground A

Routed incorrectly B

Shorted A

Terminal bent A

Terminal broken A

Terminal corroded A

Terminal loose A

Procedure

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

Require repair or replacement.

Require repair or replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require rerouting according to

vehicle manufacturer’s

specifications.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

previously diagnosed by the "perceptible movement" standard. Before requiring or suggesting any parts be replaced based on "perceptible movement," consult your repair manual to determine if OEM specifications exist.

You are not required to replace ball joints in axle sets. However, when replacing a ball joint due to wear exceeding manufacturer’s specification, you may suggest replacement of the other ball joint if its measurement shows it is close to the end of its useful life, for preventive maintenance.

BALL JOINT INSPECTION

Condition Code

Attaching hardware bent . B

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity

Attaching hardware

incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped

(threads missing) A

Binding A

Grease boot cracked 2

Grease boot missing 2

Grease boot torn 2

Grease fitting broken ... A

Grease fitting missing .. R

Grease fitting won’t seal ..

Greaseable ball joint will

Procedure

Require repair or replacement

of bent part if available;

otherwise, replace ball joint.

Require replacement of broken

part if available; otherwise,

replace ball joint.

Require replacement of corroded

part if available; otherwise,

replace ball joint.

Require replacement of

incorrect part if available; otherwise, replace ball joint.

Require repair or replacement

of loose part if available;

otherwise, replace ball joint.

Require replacement of missing

part if available; otherwise,

replace ball joint.

Require repair or replacement

of part with damaged threads if

available; otherwise, replace

ball joint.

Require replacement of part

with stripped threads if

available; otherwise, replace

ball joint.

(1) Further inspection

required.

.... (2) Suggest replacement.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

not take grease

Nut on ball joint loose

Pre-load adjustment

incorrect

Seized

Stud bent

Stud broken

Threads damaged

Threads stripped (threads

missing)

Wear exceeds

manufacturer’ s

specifications

2 (5) Suggest replacement of

grease fitting.

A (6) Require repair or

replacement.

Ð’ .. Require repair or replacement.

A Require replacement.

Ð’ (7) Require replacement.

A (7) Require replacement.

A .. Require repair or replacement.

A (7) Require replacement.

Ð’ Require replacement.

Condition Code

Attaching hardware bent . B

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity ... A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Procedure

Require repair or replacement

of bent part if available;

otherwise, replace bushing.

Require replacement of broken

part if available; otherwise,

replace bushing.

Require replacement of corroded

part if available; otherwise,

replace bushing.

Require replacement of

incorrect part if available; otherwise, replace bushing.

Require repair or replacement of loose part if available; otherwise, replace bushing.

Require replacement of missing

part if available; otherwise,

replace bushing.

Require repair or replacement

No service suggested or

required.

(1) - If noise isolated to bushing, suggest repair or

replacement. CAUTION: Use only approved lubricant on rubber bushings.

Petroleum-based lubricants may damage rubber bushings.

Attaching hardware threads stripped (threads missing)

Binding

Deteriorated, affecting
performance

Distorted, affecting
performance

Leaking (fluid-filled
type)

Missing

Noisy

Rubber separating from
internal metal sleeve on
bonded bushing

Seized

Shifted (out of
position)

Split

Surface cracking (weather-
checked)

A

A A A

A С

2

A A

Ð’ A

of part with damaged threads if available; otherwise, replace

bushing.

Require replacement of part

with stripped threads if

available; otherwise, replace

bushing. Require repair or replacement.

Require repair or replacement. Require repair or replacement.

Require replacement.

Require replacement.

(1) Further inspection

required.

Require replacement. Require replacement.

Require repair or replacement.
Require replacement.

Condition

Code

Procedure

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped (threads missing)

Require replacement of

incorrect part, if available; otherwise, replace center link.

Require repair or replacement

of loose part, if available;

otherwise, replace center link.

Require replacement of missing

part, if available; otherwise,

replace center link.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace center link.

Require replacement of part with stripped threads, if

available; otherwise, replace

center link.

Ð’ Require replacement.

(1) Further inspection required.

.... (2) Suggest replacement.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

.... (3) Suggest replacement. .... (4) Suggest replacement.

Binding A

Grease boot cracked Grease boot missing

Grease boot torn

Grease fitting broken

Grease fitting missing

Grease fitting
won’t seal

A

Grease seal missing 2

Grease seal torn 2

Looseness (perceptible

horizontal movement) ... 1 Looseness that is

excessive B

Seized

Stud bent B

Stud broken A

Stud loose in

taper hole A

Taper hole elongated .... A

Threads damaged A

Threads stripped

A

(threads missing) Wear exceeds manufacturer’ s specifications

Ð’ Require replacement.

Condition

Attaching hardware
broken

Code Procedure

Require replacement of broken

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Bent B

Shaft bushing surface

undersized (worn) B

Threads damaged A

Threads stripped (threads

missing) A

part, if available; otherwise, replace shaft.

Require repair or replacement

of loose part, if available;

otherwise, replace shaft.

Require replacement of missing

part, if available; otherwise,

replace shaft.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace shaft.

Require replacement of part

with stripped threads, if

available; otherwise, replace

shaft.
Require replacement.

Require replacement.

Require repair or replacement.

Require replacement.

Condition

Attaching hardware
bent

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Procedure

Require repair or replacement

of bent part, if available;

otherwise, replace control arm.

Require replacement of broken

part, if available; otherwise,

replace control arm.

Require replacement of corroded

part, if available; otherwise,

replace control arm.

Require replacement of

incorrect part, if available; otherwise, replace control arm.

Require repair or replacement

of loose part, if available;

otherwise, replace control arm.

Require replacement of missing

part, if available; otherwise,

replace control arm.

Require repair or replacement of part with damaged threads,

Attaching hardware
threads stripped
(threads missing)

Bent

Bushing hole oversized . .

Ball joint hole oversized
(loose interference or
press fit)

Corroded, affecting structural integrity

Holes distorted

Threads damaged

Threads stripped (threads
missing)

if available; otherwise, replace control arm.

A Require replacement of part

with stripped threads, if

available; otherwise, replace

control arm.

Ð’ Require replacement.

Ð’ Require replacement.

Ð’ (1) Further inspection

required.

A Require replacement.

A Require replacement.

A .. Require repair or replacement.

A Require replacement.

Condition

Code

Procedure

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped

(threads missing) A

Bent B

Binding A

Grease boot cracked 2

Grease boot missing 2

Grease boot torn 2

Grease fitting broken ... A

Require replacement of

incorrect part, if available; otherwise, replace drag link.

Require repair or replacement

of loose part, if available;

otherwise, replace drag link.

Require replacement of missing

part, if available; otherwise,

replace drag link.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace drag link.

Require replacement of part

with stripped threads, if

available; otherwise, replace

drag link.

Require replacement.

(1) Further inspection

required.

.... (2) Suggest replacement.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

Require replacement of grease

fitting.

Grease fitting missing . .

Grease fitting
won’t seal

Grease seal missing

Grease seal torn

Looseness (perceptible

horizontal movement) ... Looseness that is

excessive

Seized

Stud bent

Stud broken

Stud loose in

taper hole

Taper hole elongated

Threads damaged

Threads stripped (threads

missing)

Wear exceeds

manufacturer’ s

specifications

С ... Require replacement of grease

fitting.

A ... Require replacement of grease

fitting.

2 (5) Suggest replacement.

2 (4) Suggest replacement.

1 (6) Suggest replacement.

Ð’ (6)(7) Require replacement.

A Require replacement.

Ð’ (8) Require replacement.

A (8) Require replacement.

A (8) Require repair or

replacement.

A (9) Require replacement.

A .. Require repair or replacement.

A (8) Require replacement.

Ð’ Require replacement.

Code

Condition

Connector bent A

Connector broken A

Connector loose A

Electronic valve control

Procedure

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

inoperative 2

Terminal bent A

Terminal broken A

Terminal corroded A

Terminal loose A

(1) Suggest replacement.

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

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped

(threads missing) A

Binding A

Grease boot cracked 2

Grease boot missing 2

Grease boot torn 2

Grease fitting broken ... A

Grease fitting missing .. R

Grease fitting

won’t seal A

Grease seal missing 2

Grease seal torn 2

Greaseable joint will not

take grease 2

Looseness at frame

bracket end B

Require replacement of broken

part, if available; otherwise,

replace idler arm.

Require replacement of

incorrect part, if available; otherwise, replace idler arm.

Require repair or replacement

of loose part, if available;

otherwise, replace idler arm.

Require replacement of missing

part, if available; otherwise,

replace idler arm.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace idler arm.

Require replacement of part

with stripped threads, if

available; otherwise, replace

idler arm.

(1) Further inspection

required.

.... (2) Suggest replacement.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

.... (5) Suggest replacement. .... (4) Suggest replacement.

(1) Suggest replacement of grease fitting.

.... (6)(7) Require repair or replacement.

Looseness at link end
(perceptible horizontal
movement)

Looseness at link end
that is excessive

Mounted out of position
(center link
not parallel)

Nut on stud loose

Seized

Stud bent

Stud broken

Taper hole elongated

Threads damaged

Threads stripped (threads

missing)

Wear exceeds

manufacturer’ s

specifications

1 (8) Suggest replacement.

Ð’ (8)(9) Require replacement.

Ð’ Require repositioning.

A (10) Require repair or

replacement.

A Require replacement.

Ð’ (11) Require replacement.

A (11) Require replacement.

A (12) Require replacement.

A .. Require repair or replacement.

A (11) Require replacement.

Ð’ Require replacement.

Code

Condition

Bearing balls pitted

Bearing balls worn

Bearing races pitted

Procedure

A Require replacement.

A Require replacement.

A Require replacement.

Bearing races worn A

Bearing rollers pitted .. A

Bearing rollers worn .... A

Bearing seal bent 2

Bearing seal missing .... 2

Bearing seal torn 2

Binding A

End caps missing C

End play exceeds

specifications B

Grease fitting broken ... A

Grease fitting missing

Grease fitting
won’t seal

Locating pins missing

Looseness exceeds
manufacturer’ s
specifications B

Seized A

Threads damaged A

Threads stripped (threads

missing) A

Will not take grease .... 2

Require replacement.

Require replacement.

Require replacement.

Suggest replacement of seal or

bearing.

Suggest replacement of seal or

bearing.

Suggest replacement of seal or

bearing.

Require repair or replacement

of affected parts.

Require replacement of missing

part, if available; otherwise,

replace king pin.

Require repair.

Require replacement of grease

fitting. Require replacement of grease

fitting.

Require replacement of grease

fitting.

Require replacement of missing

part, if available; otherwise,

replace king pin.

.. Require replacement of worn

parts.

Require replacement.

Require repair or replacement.

.... Require replacement.

(1) Suggest replacement of

grease fitting.

Attaching hardware
threads stripped
(threads missing)

Bent

Binding

Grease boot cracked

Grease boot missing

Grease boot torn

Grease fitting broken

Grease fitting missing . .

Grease fitting
won’t seal

Grease seal missing

Grease seal torn

Looseness (perceptible horizontal movement)

Looseness that is
excessive

Nut on stud loose

Seized

Splines damaged

Splines stripped

(splines missing)

Stud bent

Stud broken

Stud loose in

taper hole

Taper hole elongated

Threads damaged

Threads stripped (threads
missing)

replace pitman arm.

A Require replacement of part

with stripped threads, if

available; otherwise, replace

pitman arm.

Ð’ Require replacement.

A (1) Further inspection

required.

2 (2) Suggest replacement.

2 (3) Suggest replacement.

2 (4) Suggest replacement.

A Require replacement grease

fitting.

С ... Require replacement of grease

fitting.

A ... Require replacement of grease

fitting.

2 (3) Suggest replacement

of seal.

2 (4) Suggest replacement

of seal.

1 (5) Suggest replacement.

Ð’ (5)(6) Require replacement.

A (7) Require repair or

replacement.

A Require replacement.

A .. Require repair or replacement.

A Require replacement.

Ð’ (8) Require replacement.

A (8) Require replacement.

A (8) Require repair or

replacement.

A (9) Require replacement.

A .. Require repair or replacement.

A (8) Require replacement.

POWER STEERING HOSES

POWER STEERING HOSE INSPECTION

Condition

Blistered B

Blocked A

Fitting threads damaged . A Fitting threads stripped

(threads missing) A

Inner fabric

(webbing) cut A

Leaking A

Missing C

Outer covering is cracked

to the extent that

the inner fabric of

hose is visible B

Restricted A

Procedure

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require replacement.

Require replacement.

Require repair or replacement.
Require replacement.

Require replacement.

Require repair or replacement.

Pulley bent A

Belt tension out of specification

Belt worn beyond

adjustment range

Belt worn so it contacts

bottom of pulley

Binding

Fluid at or beyond

service interval

Fluid contaminated

Fluid level incorrect

Inadequate assist

Leaking Noise

Pulley missing
Remote reservoir
leaking

Reservoir cap broken Reservoir cap missing

Seized

Threads damaged

Threads stripped (threads missing)

Ð’ Require adjustment or

replacement.

Ð’ Require replacement.

A Require replacement.

A .. Require repair or replacement.

3 Suggest fluid change.

Ð’ (3) Require flushing and

refilling of the system.

Ð’ Require adjustment of fluid

level.

A (4) Further inspection

required. A .. Require repair or replacement.

2 (5) Further inspection

required.

Require repair or replacement

of pulley. Require replacement of pulley.

A Require replacement of

reservoir,

A Require replacement of cap.

С Require replacement of cap.

A Require replacement.

A .. Require repair or replacement.

A Require replacement.

13. -

14. -

15. -

16. -

17. -

Determine cause of incorrect alignment and require repair.

Determine cause of noise and suggest repair.

Determine and correct source of contamination. OEM

specifications must be followed for fluid type.

If pump is source of inadequate assist, require

repair or replacement.

If noise is isolated to pump, suggest repair or

replacement.

Condition

Code

Procedure

Attaching hardware
threads stripped
(threads missing) A

Bent B

Corroded, affecting

structural integrity ... A

Holes distorted A

Threads damaged A

Threads stripped

(threads missing) A

Require replacement of part

with stripped threads.

Require replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require replacement.

Condition

Code

Procedure

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped

(threads missing) A

Bent B

Binding A

Grease boot cracked 2

Grease boot missing 2

Grease boot torn 2

Grease fitting broken ... A

Grease fitting missing

Grease fitting

won’t seal A

Grease seal missing 2

Grease seal torn 2

Looseness (perceptible

horizontal movement) ... 1
Looseness that is

excessive B

Seized A

Stud bent B

Require replacement of

incorrect part, if available; otherwise, replace relay rod.

Require repair or replacement

of loose part, if available;

otherwise, replace relay rod.

Require replacement of missing

part, if available; otherwise,

replace relay rod.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace relay rod.

Require replacement of part

with stripped threads, if

available; otherwise, replace

relay rod.

Require replacement.

(1) Further inspection

required.

.... (2) Suggest replacement.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

Require replacement grease

fitting.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

.... (3) Suggest replacement. .... (4) Suggest replacement.

.... (5) Suggest replacement.

(5)(6) Require replacement.

Require replacement.

.... (7) Require replacement.

Stud loose in

taper hole A (7) Require repair or

replacement.

Taper hole elongated .... A (8) Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A (7) Require replacement.

Wear exceeds

manufacturer’ s

specifications B Require replacement.

(1) - If greaseable, grease joint. If problem persists or

joint is non-greaseable, require replacement.

(2) - Cracked grease boot will allow contaminants to enter

the joint and will accelerate wear.

(3) - Lack of grease boot will allow contaminants to enter

the joint and will accelerate wear.

(4) - Torn grease boot will allow contaminants to enter the

joint and will accelerate wear.

(5) - If manufacturer’s procedures for inspection exist, use

those procedures; otherwise, use an approved inspection method such as the dry park check. CAUTION: DO NOT use pliers or pry bar to check ball and

socket movement. Use only moderate hand pressure.

(6) - Excessive looseness is defined as being significant

enough to affect vehicle handling or structural integrity.

18. - Check for damaged taper hole.

19. - Check for damaged stud.

SHOCK ABSORBERS, STRUT CARTRIDGES AND STRUT ASSEMBLIES

You are not required to replace shocks or struts in axle sets. However, when replacing a shock or strut due to the conditions that follow, you may suggest replacement of the other shock or strut on the same axle for improved performance and preventive maintenance.

65535. Part is close to the end of its useful life

65536. To extend tire life

65537. To balance ride and handling

65538. To improve stopping distance

When replacing steering and/or suspension components which may affect an alignment angle, you are required to check and adjust alignment as needed. Refer to the OEM specifications.

Under no circumstances should a technician bend struts or strut housings.

A vehicle’s load-carrying and handling abilities are limited by its suspension, tires, brakes, and driveline. Installing coil over shocks or any other load assist device does not increase the vehicle’s load capacity. See the vehicle owner’s manual for more details.

NOTE: If vehicle is equipped with original equipment coil over shocks, apply the conditions for coil springs from the SPRINGS - COIL, LEAF AND TORSION BAR section of the STEERING AND SUSPENSION guidelines. If the vehicle is equipped with add-on coil over shocks, you may suggest replacing the shocks with standard shocks for any spring-related condition.

SHOCK ABSORBER, STRUT CARTRIDGE AND STRUT ASSEMBLY INSPECTION

Condition Code

Attaching hardware bent . B

Attaching hardware
broken

A

A

A

Attaching hardware
missing

Attaching hardware threads damaged

Attaching hardware
threads stripped
(threads missing) A

Binding A

Body dented A

Body punctured A

Brake hose bracket

bent B

Brake hose bracket

missing C

Brake hose bracket

threads damaged A

Brake hose bracket

threads stripped

(threads missing) C

Compression bumper

missing C

Compression bumper
split 1

Damping (none) A

Dust boot (bellows)
split 2

Procedure

Require repair or replacement of bent part, if available; otherwise, replace shock or

strut.

Require replacement of broken

part, if available; otherwise,

replace shock or strut.

Require replacement of corroded

part, if available; otherwise,

replace shock or strut.

Require replacement of

incorrect part, if available; otherwise, replace shock or

strut.

Require repair or replacement

of loose part, if available;

otherwise, replace shock or

strut.

Require replacement of missing

part, if available; otherwise,

replace shock or strut.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace shock or strut.

Require replacement of part

with stripped threads, if

available; otherwise, replace

shock or strut.

Require replacement.

(1) Further inspection

required.
Require replacement.

Require repair or replacement.

Require replacement.

Require repair or replacement.

Require replacement.

Require replacement of compression bumper.

Suggest replacement of

compression bumper.

Require replacement.

(2) Suggest replacement of boot.

Strut housing cap (gland

nut) threads stripped

(threads missing) A Require replacement of nut.

Strut housing severely

corroded, affecting

structural integrity ... A Require replacement.

Strut housing threads

damaged A . . Require repair or replacement.

Strut housing threads

stripped (threads

missing) A Require replacement.

Tire cupping A (6) Further inspection

required.

Dust boot (bellows)
missing

Dust boot (bellows)
torn

Dust shield broken

Dust shield missing

Gland nut (strut housing cap) is not removable using appropriate tool

Gland nut (strut housing cap) threads damaged

Gland nut (strut housing
cap) threads stripped
(threads missing)

Housing dented

Housing punctured

Jounce bumper missing .. .

Jounce bumper split

Leaking oil, enough for
fluid to be running down
the body

Noise

Piston rod bent

Piston rod broken

Piston rod has surface

defect

Piston rod threads

damaged

Piston rod threads

stripped (threads

missing)

Seized

Shock missing

Strut housing bent

Strut housing cap (gland

nut) is not removable

using appropriate tool

Strut housing cap (gland nut) threads damaged

2 (2) Suggest replacement

of boot.

2 (2) Suggest replacement

of boot.

2 (2) Suggest replacement.

2 (2) Suggest replacement.

A .. (3) Require replacement of nut

and/or housing.

A ... Require repair or replacement

of nut.

A Require replacement of nut.

A (1) Further inspection

required.

A Require replacement.

С ... Require replacement of jounce

bumper. 1 ... Suggest replacement of jounce

bumper.

A (4) Require replacement.

2 (5) Further inspection

required.

A Require replacement.

A Require replacement.

2 Suggest replacement.

A .. Require repair or replacement.

A Require replacement.

A Require replacement.

С Require replacement.

A Require replacement.

A (3) Require replacement

of nut and/or housing.

A ... Require repair or replacement

of nut.

(1) - Require replacement of units where dents restrict shock

or strut piston rod movement. If dents don’t restrict movement, no service is suggested or required. Especially critical on mono-tube shocks.

(2) - This condition can lead to damage of the piston rod,

which, in turn, causes premature piston rod seal wear.

20. - Only required if replacing cartridge.

21. - CAUTION: If the strut cartridge has been replaced previously,

the oil on the strut housing may be filler oil. The technician must identify the source of the oil.

(5) - If noise is isolated to shock or strut, suggest

replacement.

(6) - Although shocks or struts may have contributed to tire

cupping, an inspection is needed of the entire suspension system. If the shock or strut is found to be contributing to the tire cupping, require replacement.

SPINDLES

SPINDLE INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Bent B

Broken A

Race seat area

undersized B

Scored A

Threads damaged A

Threads stripped (threads

missing) A

Require replacement of broken

part.

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

Require replacement.

Require replacement.

Require replacement.

Require repair or replacement. Require repair or replacement.

Require replacement.

Condition Code Procedure

Attaching hardware

bent B .... Require repair or replacement

of bent part. Attaching hardware

broken A .... Require replacement of broken

part.

Attaching hardware corroded, affecting

structural integrity .. A .. Require replacement of corroded

part. Attaching hardware

incorrect A Require replacement of

incorrect part. Attaching hardware

loose A .... Require repair or replacement

of loose part. Attaching hardware

missing C ... Require replacement of missing

part. Attaching hardware

threads damaged A .... Require repair or replacement

of part with damaged threads. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads. Broken (all springs except secondary leave(s) on multi-leaf

springs) A Require replacement.

Coil clash (1) Require ride height check.

Coil spring insulator

deteriorated 2 Suggest replacement of

insulator. Coil spring insulator

missing 2 Suggest replacement of

insulator. Coil spring insulator

split 2 Suggest replacement of

insulator. Coil spring plastic coating deteriorated -

rust present A (2) Refer to manufacturer’s

service requirements. Composite spring

damaged (3) Further inspection

required.

Cracked (all springs except composite leaf and secondary leave(s) on

multi-leaf springs) ... A Require replacement.

Installed incorrectly .. B Require repair.

Leaf spring insulators

missing 2 Suggest replacement of

insulators.

Secondary leaf on multi-leaf spring broken .... 1 .... Suggest repair or replacement Secondary leaf on multi-leaf spring cracked ... 1 .... Suggest repair or replacement Torsion bar

adjuster bent A (4) Require repair or

replacement of adjuster. Torsion bar adjuster

seized A .... (4) Require repair or replacement

of adjuster. Torsion bar adjuster

threads damaged A .... (4) Require repair or replacement

of part with damaged threads. Torsion bar adjuster threads stripped

(threads missing) A Require replacement of part

with stripped threads. Vehicle suspension height not within OEM

specifications B Require adjustment or

replacement.

(1) - If vehicle is within manufacturer’s height

specifications, no service is suggested or required.

(2) - Some manufacturers require replacement under these

conditions.

(3) - Check vehicle ride height. If ride height is OK, no

service is suggested or required.

(4) - Only required if ride height needs to be adjusted.

STEEL POWER STEERING LINES

CAUTION: When replacing steel power steering lines, be sure to use a replacement product that meets or exceeds OEM design specifications.

STEEL POWER STEERING LINE INSPECTION

Condition Code Procedure

Attaching hardware

bent B ... Require repair or replacement

of bent part. Attaching hardware

broken A ... Require replacement of broken

part. Attaching hardware

loose A ... Require repair or replacement

of loose part. Attaching hardware

missing C . . Require replacement of missing

part. Attaching hardware

threads damaged A ... Require repair or replacement

of part with damaged threads. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads.

Blocked A . . Require repair or replacement.

Fitting incorrect (such as compression

fitting) B Require replacement.

Flare type incorrect .... B Required replacement.

Leaking A Require tightening or

replacement.
Line type incorrect B Require replacement.

Restricted A Require replacement.

Routed incorrectly B Require routing correction.

Rust-pitted 1 Suggest replacement.

Rust pitted, affecting

structural integrity .. A Require replacement.

STEERING ARMS

STEERING ARM INSPECTION

Condition

Code

Procedure

Attaching hardware
bent B

Attaching hardware
broken A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Bent B

Broken A

Taper hole elongated .... A

Threads damaged A

Threads stripped (threads

missing) A

(1) - Check for damaged stud.

Require repair or replacement of bent part.

Require replacement of broken

part.

Require replacement of incorrect part.

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

Require replacement.

Require replacement.

(1) Require replacement.

Require repair or replacement.

Require replacement.

Condition Code

Attaching hardware bent . B

Attaching hardware
broken

Procedure

Require repair or replacement of bent part, if available; otherwise, replace steering

damper.

Require replacement of broken part, if available; otherwise,

replace steering damper. Attaching hardware corroded, affecting

structural integrity ... A . Require replacement of corroded

part, if available; otherwise, replace steering damper. Attaching hardware

incorrect A Require replacement of

incorrect part, if available; otherwise, replace steering

damper. Attaching hardware

loose A ... Require repair or replacement

of loose part, if available; otherwise, replace steering

damper. Attaching hardware

missing C . . Require replacement of missing

part, if available; otherwise, replace steering damper. Attaching hardware

threads damaged A ... Require repair or replacement

of part with damaged threads, if available; otherwise, replace steering damper. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads, if

available; otherwise, replace

steering damper.

Binding A Require replacement.

Damper body dented A (1) Further inspection

required.

Damper body punctured ... A Require replacement.

Damping (none) A Require replacement.

Dust boot (bellows)

missing 2 (2) Suggest replacement

of boot. Dust boot (bellows)

split 2 (2) Suggest replacement

of boot.

Dust shield broken 2 (2) Suggest replacement.

Dust shield missing 2 (2) Suggest replacement.

Leaking oil, enough for fluid to be running

down the body A Require replacement.

Loose A . . Require repair or replacement.

Missing C Require replacement.

Noise 2 (3) Further inspection

required.

Piston rod bent A Require replacement.

Piston rod broken A Require replacement.

Piston rod has surface

defect 2 Suggest replacement.

Piston rod threads stripped (threads

missing) A Require replacement.

Piston rod threads

damaged A . . Require repair or replacement.

Seized A Require replacement.

(1) - Require replacement of units where dents restrict damper

piston rod movement. If dents don’t restrict movement, no service is suggested or required. Especially critical on mono-tube dampers.

(2) - This condition can lead to damage of the piston rod,

which, in turn, causes premature piston rod seal wear.

(3) - If noise is isolated to damper, suggest replacement.

STEERING GEARS (EXCEPT RACK AND PINION)

If diagnosis has determined that complete disassembly is necessary to determine the extent of the system failure, the suggestion may be made to rebuild or replace the power steering pump. Repair or replacement of the following components may be required, if performed as part of a power steering pump overhaul or rebuild service to meet a minimum rebuild standard.

STEERING GEAR (EXCEPT RACK AND PINION) INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Binding A

Flex coupler binding .... A

Flex coupler loose A

Flex coupler
missing parts A

Flex coupler

soft/spongy A

Flex coupler torn A

Fluid contaminated B

Gasket leaking A

Housing leaking A

Hydraulic fittings
leaking A

Inadequate power assist . A

Lash exceeds manufacturer’ s

specifications B

Seal leaking A

Require replacement of broken

part.

Require repair or replacement of loose part.

Require replacement of missing part.

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads. Require repair or replacement Require repair or replacement of coupler.

Require repair or replacement of coupler.

Require repair or replacement of coupler.

Require replacement of coupler. Require replacement of coupler.

(1) Require flushing and

refilling of the system. Require repair or replacement

of gasket.
Require replacement.

Require repair or replacement of fittings.

(2) Further inspection

required. See note below.

Require repair or replacement. Require repair or replacement

(1) - Determine and correct source of contamination. OEM

specifications must be followed for fluid type.

(2) - If steering gear is source of inadequate assist, require

repair or replacement.

Splines damaged A

Splines stripped A

Steering coupler

shield cracked 2

Steering coupler

shield missing C

Threads damaged A

Threads stripped

(threads missing) A

U-joint binding A

U-joint loose A

Unequal power assist .... A

of seal and/or mating part.

Require repair or replacement

of splines.

Require replacement of splines.

Suggest replacement.

Require replacement.

Require repair or replacement of part with damaged threads.

Require replacement of part

with stripped threads.

Require repair or replacement

of joint.

Require repair or replacement

of joint. Require repair or replacement.

Condition

Code

Procedure

2 С

(not through)

Bellows boot missing

Bellows boot

not sealing A

Bellows boot torn A

Bellows boot twisted

(from toe adjustment) .. R

Fitting leaking A

Fitting missing A

Fitting threads

damaged A

Fitting threads stripped

(threads missing) A

Flex coupler binding .... A

Flex coupler loose A

Flex coupler

missing parts A

Flex coupler

soft/spongy A

Flex coupler torn A

Fluid contaminated B

Gasket leaking A

Hard steering on cold

start-up 1

Housing cracked,

affecting structural

integrity B

Housing leaking A

Inadequate power assist . A

Lash exceeds

manufacturer’ s

specifications B

Seal leaking A

Splines damaged A

Splines stripped

(splines missing) A

Steel line blocked A

Steel line leaking A

Steel line missing C

Steel line restricted ... A

Steering coupler shield

cracked 2

Steering coupler shield

missing C

Steering coupler shield

torn 2

Threads damaged A

Suggest replacement of bellows

boot.

Require replacement of bellows

boot.

Require repair or replacement

of bellows boot.

Require replacement of bellows

boot.

Require repair.

Require repair or replacement. Require replacement of fitting.

Require repair or replacement of part with damaged threads.

Require replacement of part

with stripped threads.

Require repair or replacement

of coupler.

Require repair or replacement of coupler.

Require repair or replacement of coupler.

Require replacement of coupler. Require replacement of coupler.

(1) Require flushing and

refilling of the system. Require repair or replacement.

(2) Suggest repair or

replacement.

Require replacement.

Require replacement.

(3) Further inspection

required.

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

Require replacement.

Require repair or replacement

of line.

Require repair or replacement

of line.

Require replacement of line. Require repair or replacement

of line.

Suggest replacement.

Require replacement.

Suggest replacement.

Require repair or replacement of part with damaged threads.

Threads stripped

(threads missing) A Require replacement of part

with stripped threads.

U-joint binding A ... Require repair or replacement

of joint.

U-joint loose A ... Require repair or replacement

of joint. Unequal power assist .... A .. Require repair or replacement.

(1) - Determine and correct source of contamination. Follow OE

specifications for fluid type.

22. - Indicates internal wear.

23. - If steering gear is source of inadequate assist, require

repair or replacement.

STEERING KNUCKLES

STEERING KNUCKLE INSPECTION

Condition

Code

Procedure

Attaching hardware
bent

Attaching hardware
broken

Attaching hardware
incorrect

Attaching hardware
loose

Attaching hardware
missing

Attaching hardware
threads damaged A

Attaching hardware threads stripped (threads missing)

Bent B

Broken A

Pinch bolt incorrect .... B

Pinch bolt loose B

Pinch bolt missing B

Pinch bolt tabs

deformed (pinched

together), .032"

or more before

clamping B

Taper hole elongated .... A

Threads damaged A

Threads stripped (threads

missing) A

Require repair or replacement of bent part.

Require replacement of broken

part.

Require replacement of incorrect part.

Require repair or replacement of loose part.

Require replacement of missing

part.

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

Require replacement.

Require replacement.

Require replacement with bolt that meets OE design.

Require repair.

Require replacement.

(1) Require replacement.

(2) Require replacement.

Require repair or replacement.

Require repair or replacement.

STRIKE OUT BUMPERS

STRIKE OUT BUMPER INSPECTION
Condition Code

Attaching hardware
broken A

Attaching hardware corroded, affecting structural integrity ... A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Missing C

Split 1

Procedure

Require replacement of

broken part.

Require replacement of

corroded part.

Require repair or replacement of loose part.

Require replacement of

missing part.

Require repair or replacement of part with damaged threads.

Require replacement of part with stripped threads.

Require replacement.

Suggest replacement.

STRUT RODS

STRUT ROD INSPECTION
Condition Code

Adjusting nut seized .... A

Attaching hardware
bent B

Attaching hardware
broken A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Procedure

1) Require repair or replacement.

Require repair or replacement

of bent part, if available;

otherwise, replace strut rod.

Require replacement of broken

part, if available; otherwise,

replace strut rod.

Require replacement of

incorrect part, if available; otherwise, replace strut rod.

Require repair or replacement

of loose part, if available;

otherwise, replace strut rod.

Require replacement of missing

part, if available; otherwise,

replace strut rod.

Require repair or replacement of part with damaged threads,

if available; otherwise, replace strut rod. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads, if available; otherwise, replace

strut rod. Attaching (mating) hole

oversized A ... Require repair or replacement

of frame.

Attaching point on frame corroded, affecting

structural integrity ... A Require repair of frame.

Bent A Require replacement.

Mating (attaching) hole

oversized A ... Require repair or replacement

of frame.

Threads damaged A .. Require repair or replacement.

Threads stripped
(threads missing) A Require replacement.

(1) - Only required if an alignment is being performed.

STRUT UPPER BEARING PLATE ASSEMBLIES

NOTE: When the following guidelines indicate replacement of bearing, only the bearing should be replaced if it is available separately; otherwise, replace the bearing plate assembly.

STRUT UPPER BEARING PLATE ASSEMBLY INSPECTION

Condition Code Procedure

Attaching hardware

broken A ... Require replacement of broken

part, if available; otherwise, replace bearing plate assembly. Attaching hardware

loose A ... Require repair or replacement

of loose part, if available; otherwise, replace bearing plate assembly. Attaching hardware

missing C . . Require replacement of missing

part, if available; otherwise, replace bearing plate assembly. Attaching hardware

threads damaged A ... Require repair or replacement

of part with damaged threads, if available; otherwise, replace bearing plate assembly. Attaching hardware threads stripped

(threads missing) A Require replacement of part

with stripped threads, if available; otherwise, replace bearing plate assembly. Bearing axial or radial movement exceeds vehicle manufacturer’ s

specifications B

Bearing binding A

Bearing missing C

Bearing seized A

Bent B

Holes distorted A

Missing C

Severely corroded, affecting structural

integrity A

Require replacement

of bearing.

Require replacement

of bearing.

Require replacement

of bearing.

Require replacement

of bearing.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Condition

Code

Procedure

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped (threads missing)

Ball and socket has looseness (perceptible

vertical movement) 1

Ball and socket has looseness that is

excessive B

Bent B

Broken A

Corroded, affecting

structural integrity ... A

Grease boot cracked 2

Grease boot missing 2

Grease boot torn 2

Missing C

Nut on stud loose A

Stud bent B

Stud broken A

Threads damaged A

Require replacement of

incorrect part, if available; otherwise, replace link.

Require repair or replacement

of loose part, if available;

otherwise, replace link.

Require replacement of missing

part, if available; otherwise,

replace link.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace link.

Require replacement of part

with stripped threads, if

available; otherwise, replace

link.

(1) Suggest replacement.

(1)(2) Require replacement.

Require replacement.

Require replacement.

Require replacement.

(3) Suggest replacement.

(4) Suggest replacement.

(5) Suggest replacement.

Require replacement.

(6) Require repair.

(7) Require replacement.

(7) Require replacement.

Require repair or replacement.

Threads stripped (threads
missing)

A

(7) Require replacement.

Condition

Attaching hardware
broken

Attaching hardware corroded, affecting structural integrity

Attaching hardware
loose A

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware
threads stripped
(threads missing) A

Bent B

Broken A

Threads damaged A

Threads stripped

(threads missing) A

Procedure

Require replacement of broken

part, if available; otherwise,

replace sway bar.

Require replacement of

corroded part, if available; otherwise, replace sway bar.

Require repair or replacement of loose part, if available; otherwise, replace sway bar.

Require replacement of missing

part, if available; otherwise,

replace sway bar.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace sway bar.

Require replacement of part

with stripped threads, if

available; otherwise, replace

sway bar.

Require replacement.

Require replacement.

Require repair or replacement.

Require replacement.

TIE ROD END (INNER AND OUTER) INSPECTION

Condition

Code

Procedure

Attaching hardware
incorrect

Attaching hardware
loose

Attaching hardware
missing

Attaching hardware threads damaged

Attaching hardware threads stripped (threads missing)

Adjusting sleeve bent ... B

Adjusting sleeve clamps
out of position B

Adjusting sleeve corroded, affecting structural integrity ... A

Adjusting sleeve
missing C

Adjusting sleeve
seized

Adjusting sleeve
threads damaged A

Adjusting sleeve
threads stripped
(threads missing) A

Binding A

Grease boot cracked Grease boot missing

Grease boot torn

Grease fitting broken

Grease fitting missing

Grease fitting
won’t seal

Grease seal missing

Require replacement of

incorrect part, if available; otherwise, replace tie rod end.

Require repair or replacement

of loose part, if available;

otherwise, replace tie rod end.

Require replacement of missing

part, if available; otherwise,

replace tie rod end.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace tie rod end.

Require replacement of part

with stripped threads, if

available; otherwise, replace

tie rod end.

Require replacement of sleeve or tie rod end.

Require repair.

Require replacement of sleeve or tie rod end.

Require replacement of sleeve or tie rod end.

1) Require repair or replacement.

Require repair or replacement of sleeve or tie rod end.

Require replacement of sleeve or tie rod end.

(2) Further inspection

required.

.... (3) Suggest replacement.

.... (4) Suggest replacement.

.... (5) Suggest replacement.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

Require replacement of grease

fitting.

(4) Suggest replacement

of seal.

Grease seal torn 2 (5) Suggest replacement

of seal. Greaseable tie rod end

won’t take grease 2 (6) Suggest replacement of

grease fitting. Looseness (perceptible

horizontal movement) ... 1 (7) Suggest replacement.

Looseness exceeds

manufacturer’ s

specifications B Require replacement.

Looseness that is

excessive B (7)(8) Require replacement.

Nut on stud loose A (9) Require repair or

replacement of nut.

Seized A Require replacement

Stud bent B (10) Require replacement.

Stud broken A (10) Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped

(threads missing) A (10) Require replacement.

24. - Only required if toe needs to be adjusted.

25. - If greaseable, grease joint. If problem persists or

joint is non-greaseable, require replacement.

(3) - Cracked grease boot will allow contaminants to enter

joint and will accelerate wear.

(4) - Lack of grease boot will allow contaminants to enter

joint and will accelerate wear.

(5) - Torn grease boot will allow contaminants to enter joint

and will accelerate wear.

(6) - If greaseable tie rod end will not take grease after

replacing the grease fitting, suggest replacement of tie rod end.

(7) - If manufacturer’s procedures for inspection exist, use

those procedures; otherwise, use an approved inspection method such as the dry park check.

CAUTION: DO NOT use pliers or pry bar to check ball and socket movement. Use only moderate hand pressure.

(8) - Excessive looseness is defined as being significant enough

to affect vehicle handling or structural integrity.

(9) - Check for bent stud or damaged taper hole.

(10) - Check for damaged taper hole.

TRACK BARS

TRACK BAR INSPECTION

Condition Code Procedure

Attaching hardware

incorrect A Require replacement of

incorrect part, if available; otherwise, replace track bar. Attaching hardware

loose A ... Require repair or replacement

of loose part, if available; otherwise, replace track bar. Attaching hardware

missing C . . Require replacement of missing

part, if available; otherwise, replace track bar. Attaching hardware

threads damaged A

Attaching hardware
threads stripped
(threads missing)

Bent

Corroded, affecting structural integrity

Grease boot cracked

Grease boot missing

Grease boot torn

Holes distorted

Looseness (perceptible horizontal movement)

Looseness that is
excessive

Nut on stud loose

Seized

Stud bent

Stud broken

Threads damaged

Threads stripped (threads

missing)

Wear exceeds

manufacturer’ s

specifications

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace track bar.

A Require replacement of part

with stripped threads, if available; otherwise, replace

track bar.
Ð’ Require replacement.

A Require replacement.

2 (1) Suggest replacement.

2 (2) Suggest replacement.

2 (3) Suggest replacement.

A Require replacement.

1 (4) Suggest replacement.

Ð’ (4)(5) Require replacement.

A (6) Require repair or

replacement of nut.

A Require replacement.

Ð’ (7) Require replacement.

A (7) Require replacement.

A .. Require repair or replacement.

A (7) Require replacement.

Ð’ Require replacement.

Condition

Attaching hardware
broken

Attaching hardware
loose

Code Procedure

A ... Require replacement of broken

part, if available; otherwise,

replace trailing arm.

A ... Require repair or replacement of loose part, if available;

Attaching hardware
missing

Attaching hardware threads damaged

Attaching hardware
threads stripped
(threads missing) A

Bent B

Bushing hole oversized .. R
Corroded, affecting

structural integrity ... A

Holes distorted A

Threads damaged A

Threads stripped

(threads missing) A

otherwise, replace trailing

arm.

Require replacement of missing

part, if available; otherwise,

replace trailing arm.

Require repair or replacement

of part with damaged threads,

if available; otherwise,

replace trailing arm.

Require replacement of part

with stripped threads, if

available; otherwise, replace

trailing arm.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require replacement.

Condition Code

Rear axle seal on rear-wheel drive leaking .... A

Seal bent 1

Seal leaking A

Seal missing C

Seal torn A

Wheel bearing

assembly feels rough

when rotated A

Wheel bearing balls

are pitted A

Wheel bearing balls
are worn

Wheel bearing end-play
exceeds vehicle
manufacturer’s
specifications

Procedure

Require replacement of seal

and inspection of axle,

bearing, housing,

and vent tube.

Suggest replacement.

Require replacement of seal and inspection of bearings.

Require replacement.

Require replacement.

Require replacement of bearing

assembly.

Require replacement of bearing

assembly.

Require replacement of bearing

assembly.

Require adjustment of bearing,

if possible. If proper adjustment cannot be obtained, require repair or replacement of worn component. Wheel bearing race is loose in the

hub bore A Require replacement of hub

assembly and wheel bearings. Wheel bearing races

are pitted A .. Require replacement of bearing

assembly. Wheel bearing races

are worn A . . Require replacement of bearing

assembly. Wheel bearing rollers

are pitted A .. Require replacement of bearing

assembly. Wheel bearing rollers

are worn A . . Require replacement of bearing

assembly.

WHEEL ALIGNMENT

WHEEL ALIGNMENT

Wheel alignment is defined as the measurement, analysis, and adjustment of steering and suspension angles to conform to OEM specifications. These angles usually include, but are not limited to: caster, camber, toe, and thrust angle. Where these angles are not adjustable and not in specification, component replacement or correction kits may be required. Errors in set-back and steering axis inclination (SAI) are often attributable to failed or damaged components and must be corrected prior to performing an alignment.

Failure to replace or correct suggested parts or service may prevent a proper alignment.

Before performing an alignment check, inspect and verify the following:

65535. Tire pressure and size

65536. Vehicle loading

65537. Ride height

65538. Steering and suspension parts

If the inspection reveals that all the above are within published specifications, a wheel alignment check and an alignment, if needed, may be performed.

CAUTION: Under no circumstances should a technician bend or heat

any steering or suspension component, unless specified by the vehicle manufacturer, for example, Ford forged twin "I" beam axles. All measurements and specifications must be noted on the inspection report.

WHEEL ALIGNMENT INSPECTION

Condition Code Procedure

Dog tracking, shown

to be caused by

faulty alignment 2 Suggest repair.

Lead, shown to

be caused by

faulty alignment

Part has been changed,

affecting alignment Pull, shown to be caused

by faulty alignment . . . Steering wheel

off-center

Tire wear, shown

to be caused by

faulty alignment

Wander, shown

to be caused by

faulty alignment

A Require alignment.

A Require alignment check.

A Require alignment.

2 Suggest alignment.

A Require alignment.

A Require alignment.

Condition Code Procedure

Air pressure incorrect . . B Require repair

Bead broken A Require replacement.

Bead leaking, caused

by tire A . . Require repair or replacement.

Bead wire/cord exposed .. A Require replacement.

Cord or belt material

exposed A Require replacement.

Cord ply separations .... A Require replacement.

Directional/asymmetrical

tires mounted

incorrectly B Require remounting and/or

repositioning. Irregular tread wear,

affecting performance .. 2 (1) Suggest replacement.

Load ratings less

than OEM

specifications B Require replacement.

Mixed tread types (all

season, performance, mud

and snow) on same axle . A Require replacement.

Number of punctures

exceeds manufacturer’ s

limit B Require replacement.

Out of balance B . Require rebalance of tire/wheel

assembly.

Ply separation A Require replacement.

Pull or lead, caused

by tire A . . Require repair or replacement.

Radial and bias or

bias-belted ply tires

on same axle B . . Require repair or replacement.

Radials are on the front

and not on the rear .... B (2) Require repair or

replacement.

Run flat damage A Require replacement.

Shoulder cut A Require replacement.

Shoulder puncture A Require replacement.

Shoulder with plug A Require replacement.

Sidewall bulge A Require replacement.

Sidewall cut A Require replacement.

Sidewall indentation No service required or

suggested.

Sidewall puncture A Require replacement.

Sidewall with plug A Require replacement.

Speed rating

designations

different

on same axle 2 . . Suggest repair or replacement.

Tire and wheel assembly

has excessive run-out . . B (3) Require repair or

replacement of appropriate

part. Tires with more than

1/4" diameter difference

on a four-wheel drive

vehicle B Require replacement.

Tread area puncture larger

in diameter than

manufacturer’ s

specifications B Require replacement.

Tread missing pieces

(chunking),

exposing cord A Require replacement.

Tread missing pieces (chunking) , not

exposing cord 1 Suggest replacement.

Tread separations A Require replacement.

Tube in tubeless tire 3 .... (4) Suggest removal of tube.

Weather-checking No service required or

suggested. Worn to tread wear

indicators B Require replacement.

28. - Determine and correct cause of irregular tire wear.

29. - If radials and bias or bias-belted ply tires are on the

same vehicle, the radials must be on the rear axle, except for high-pressure temporary spares.

(3) - Excessive is defined as enough to contribute to

performance problems. Match mounting may correct run-out. If not, require replacement of appropriate part. Refer to manufacturer’s specifications.

(4) - Most manufacturers do not recommend tubes in tubeless

tires. Inspect tire and wheel assembly to determine the reason for a tube in tubeless tire. Recommendation for repair or replacement should be based upon condition of tires and/or wheel listed in these guidelines.

VALVE STEMS

VALVE STEM INSPECTION

Condition

Code

Procedure

Bent Broken

A Require replacement.

A (1) Require replacement.

Loose B ... Require repair or replacement

of affected component. Lug nut installed

backward B . . Require repair or replacement.

Lug nut mating type

incorrect B Require replacement of nut.

Lug nut mating surface

dished A Require replacement of nut.

Lug nut rounded A . (2) Require replacement of nut.

Lug nut seized A . (2) Require replacement of nut.

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

Threads damaged A ... Require repair or replacement

of component with damaged threads.

Threads stripped A Require replacement of

component with stripped threads.

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

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

(2) - Only required if removing wheel.

WHEELS (RIMS)

WARNING: Mounting a regular tire on a high-pressure compact spare wheel is not permitted. Attempting to mount a tire of one diameter on a wheel of a different diameter or flange type may result in serious injury or death. If the wheel identification stamp is not legible, or cannot be found, do not use the wheel until the size and type have been properly identified. Wheels of different diameter, offset, or width cannot be mixed on the same axle. Bead seat tapers cannot be interchanged.

WHEEL (RIM) INSPECTION

Code

A

A

Condition

Bead leaking, caused
by wheel

Bent hub mounting

surface

Bent rim, causing

vibration

Broken

Cast wheel porous,

causing a leak

Clip-on balance weight is

incorrect type

for rim flange

Corrosion, affecting

structural integrity Corrosion build-up on

wheel mounting

surface

Cracked

Directional/asymmetrical

wheels mounted

incorrectly

Procedure

1) Require repair or replacement.

A Require replacement.

2 (1) Suggest replacement.

A Require replacement.

Require repair or replacement.

2 Suggest replacement.

A Require replacement.

A Require repair.

A Require replacement.

Ð’ Require remounting and/or

repositioning.

Load capacity less than

OEM specifications B Require replacement.

Offset mismatched

on same axle B Require replacement.

Rivets leaking A Require replacement.

Run-out beyond

OEM specs B Require replacement.

Stud holes elongated .... A (2) Require replacement.

Welded or brazed

repair 2 Suggest replacement.

Welds leaking A Require replacement.

Wheel centering (pilot)

hole incorrect B Require replacement.

30. - CAUTION: DO NOT attempt to correct a bent rim.

31. - Inspect wheel attaching hardware for damage.