* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *

1988 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

- Part does not meet a design specification (regardless of

performance) - 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:

  • Remove all components having rubber parts from the
    system.

  • Flush lines with denatured alcohol or brake cleaner

  • Repair or replace all components having rubber parts

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

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

system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct brake fluid. (Code B) (2) - 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 .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Pedal pad missing ....... C .... Require replacement of pedal pad.
Pedal pad worn .......... 1 ............ Suggest replacement.
Pivot bushings worn,
affecting performance .. A .... Require replacement of pivot
bushings.

BRAKE SHOES

See FRICTION MATERIAL.

BRAKE SHOE HARDWARE

See also SELF-ADJUSTING SYSTEMS BRAKE SHOE HARDWARE INSPECTION

Condition		Code			Procedure
Broken .................. A ............ Require replacement. 
Distorted ............... A ............ Require replacement. 
Missing ................. C ............ Require replacement. 
Surfaces rust-pitted .... 1 ............ Suggest replacement. 
Worn, affecting 
performance ............ A ............ Require replacement. 

BRAKE STOPLIGHT SWITCHES

BRAKE STOPLIGHT INSPECTION

Condition		Code			Procedure

Bent .................... B ............ Require replacement.

Broken .................. A ............ Require replacement.

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.

Missing ................. C ............ Require replacement.

Out of adjustment ....... B ........... Require adjustment or

replacement.

Output signal incorrect . B ............ Require replacement.

Terminal burned, affecting

performance ............ A .............. (2) 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.

(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 ... 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 .................. A .. Require repair or replacement.
Bulb seized in socket ... A .. Require repair or replacement.
Burned, affecting
performance ............ A .............. (1) Require repair
or replacement.
Burned, not affecting
performance ............ 2 .............. (1) Suggest repair
or replacement.
Connector broken ........ A .. Require repair or replacement.
Connector missing ....... C ............ Require replacement.
Connector (Weatherpack
type) leaking .......... A .. Require repair or replacement.
Connector melted ........ A .............. (2) Require repair
or replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Corroded, not affecting
performance ............ 2 .. Suggest repair or replacement.
Leaking ................. A .. Require repair or replacement.
Melted .................. A ........ (2) Require replacement.
Shorted ................. A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. (2) 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.
(1) - Determine cause and correct prior to repair or
replacement of socket.
(2) - Determine cause and correct prior to repair or
replacement of part.

BULBS AND LEDS

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

BULB AND LED INSPECTION

Condition Code Procedure
Application incorrect ... B ........ (1) Require replacement.
Base burned, affecting
performance ............ A .............. (2) Require repair
or replacement.
Base burned, not affecting
performance ............ 2 .............. (2) Suggest repair
or replacement.
Base corroded, affecting
performance ............ A .. Require repair or replacement.
Base corroded, not
affecting performance .. 2 .. Suggest repair or replacement.
Base loose, affecting
performance ............ B .. Require repair or replacement.
Base loose, not affecting
performance ............ 1 .. Suggest repair or replacement.
Burned out .............. A ............ Require replacement.
Intermittent ............ A ............ Require replacement.
Missing ................. C ............ Require replacement.
Seized in socket ........ A .. Require repair or replacement.
Terminal broken ......... A .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. (2) Require repair
or replacement.
Terminal burned, not
affecting performance .. 2 .............. (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.
(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


Condition Code Procedure
Bent ................... A .. Require repair or replacement.
Broken .................. A .. Require repair or replacement.
Corroded, affecting
performance ............ A .. Require repair or replacement.
Dust boots on slider pin
(bolt) missing ......... C ... Require replacement of boots.
Dust boots on slider pin
(bolt) torn ............ A ... Require replacement of boots.
Missing ................. C ............ Require replacement.
Shim bent ............... A ............. (1) Require removal
or replacement.
Shim (OE standard)
missing ................ C ........ (2) Require replacement.
Shim out of position .... B ............. (1) Require removal
or replacement.
Shim worn ............... A ............. (1) Require removal
or replacement.
Slider pin (bolt) bent .. B ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt)
rust-pitted ............ A ... Require replacement of slider
pin or bolt and lubricants.
Slider pin (bolt) worn .. A ... Require replacement of slider
pin or bolt and lubricants.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Worn, affecting
performance ............ A ............ Require replacement.
(1) - Removal is acceptable if shim is not OE.
(2) - Aftermarket shims may be 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 Procedure
Bleeder port damaged .... A ... Require repair or replacement
of caliper.
Bleeder screw broken off
in caliper ............. A ........... (1) Require repair or
replacement of caliper.
Bleeder screw plugged ... A ........... (1) Require repair or
replacement of bleeder screw.
Bleeder screw seized .... A ......... (2) Require replacement
of caliper.
Casting corroded,
affecting structural
integrity .............. A ............ Require replacement.
Casting damaged, affecting
structural integrity ... A ............ Require replacement.
Dust boot around caliper
torn ................... A ..... Require replacement of dust
boot.
Leaking ................. A .. Require repair or replacement.
Mounting pin threads
damaged ................ A ... Require repair or replacement
of component with damaged
threads.
Mounting pin threads
stripped in caliper
bracket (threads
missing) ............... A ... Require repair or replacement
of caliper bracket.
Mounting pin threads
stripped in steering
knuckle (threads
missing) ............... A ... Require repair or replacement
of steering knuckle.
Mounting pin threads
stripped (threads
missing) ............... A ... Require repair or replacement
of component with stripped
threads.
Parking brake cable
support, lever, or return
spring bent ............ A ... Require replacement of parts.
Parking brake cable
support, lever, or return
spring broken .......... A ... Require replacement of parts.
Parking brake mechanism in
caliper inoperative .... A .. Require repair or replacement.
Piston corroded (pitted
or peeling chrome
plating) ............... B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, affecting
performance ............ B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston damaged, not
affecting performance .. .. ........ No service suggested or
required.
Piston finish worn off .. B ... Require replacement of piston
and rebuilding or replacement
of caliper.
Piston sticking ......... A ........... Require rebuilding or
replacement of caliper.
Slide mechanism
sticking ............... A ... 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


Condition Code Procedure
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.
Missing ................. C ............ Require replacement.
Output signal incorrect . B .. Require repair or replacement.
Terminal burned, affecting
performance ............ A .............. (2) 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.
(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 Code Procedure
Balance weight missing .. .. ........ No service suggested or
required.
Bell-mouthed, affecting
performance ............ A ....... Require reconditioning or
replacement.
Cooling fin broken ...... .. ........ No service suggested or
required.
Cracked ................. B ............ Require replacement.
Drum diameter is greater
than OEM "machine to"
specifications but less
than "discard at"
specifications, and the
drum does not require
reconditioning ......... 1 ........ (1) Suggest replacement.
Drum diameter will exceed
OEM "machine to"
specifications after
required
reconditioning ......... B ........ (2) Require replacement.
Hard-spotted ............ 2 ....... Suggest reconditioning or
replacement.
Measured diameter is
greater than OEM discard
specifications ......... B ............ Require replacement.
Out-of-round (runout),
affecting performance .. A ....... Require reconditioning or
replacement.
Out-of-round (runout),
exceeding manufacturers
specifications ......... B ....... Require reconditioning or
replacement.
Scored .................. B ....... Require reconditioning or
replacement.
Surface threaded due to
improper machining ..... B ....... Require reconditioning or
replacement.
Tapered, affecting
performance ............ 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 ................. 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.
Contaminated ............ A ........ (2) Require replacement.
Inoperative ............. A .............. (3) Require repair
or replacement.
Leaking externally ...... A .. Require repair or replacement.
Leaking internally ...... A .. Require repair or replacement.
Noisy ................... 2 .. Suggest 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.
Threads damaged ......... A .. Require repair or replacement.
Threads stripped (threads
missing) ............... A ............ Require replacement.
Wire lead conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. 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.
(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 Code Procedure
Application incorrect ... B ............ Require replacement.
Attaching hardware
missing ................ C .......... Require replacement of
hardware.
Attaching hardware threads
damaged ................ A ... Require repair or replacement
of hardware.
Attaching hardware threads
stripped (threads
missing) ............... A ... Require repair or replacement
of hardware.
Code set (if
applicable) ............ A .......... (1) Further inspection
required.
Connector broken ........ A .. Require repair or replacement.
Connector melted ........ A ........... (2) Require repair or
replacement.
Connector missing ....... A ................. Require repair.
Contaminated ............ A .. Require repair or replacement.
Inoperative ............. B .. Require repair or replacement.
(3) Further inspection required.
Leaking ................. A .. Require repair or 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 .. 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 conductors
exposed ................ B .. Require repair or replacement.
Wire lead corroded ...... A .. Require repair or replacement.
Wire lead open .......... A .. Require repair or replacement.
Wire lead shorted ....... A .. 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


Condition Code Procedure
Contaminated, for example,
fluid that leaked from
caliper, wheel cylinder,
or axle seal ........... A ........ (1) Require replacement.
Cracked through ......... B Require replacement.
Flaking or chunking ..... B Require replacement.
Glazed (shiny) .......... .. ........ No service suggested or
required.
Grooves or ridges ....... .. .... (2) No service suggested or
required.
Permanently attached
hardware bent .......... A ............ Require replacement.
Permanently attached
hardware broken ........ A ............ Require replacement.
Permanently attached
hardware loose ......... A ............ Require replacement.
Permanently attached
hardware missing ....... C ............ Require replacement.
Permanently attached
hardware seized ........ A .. Require repair or replacement.
Rivets loose ............ B ............ Require replacement.
Separating from backing . B ............ Require replacement.
Shoe table or web bent .. B ............ Require replacement.
Shoe table or web
cracked ................ A ............ Require replacement.
Shoe table or web worn,
affecting performance .. A ............ Require replacement.
Surface cracking ........ .. ........ No service suggested or
required. Further inspection
may be necessary to determine
cause.
Tapered wear ............ B ........ (3) Suggest replacement.
Thickness of one pad is
greater than opposite pad
in the same caliper
(uneven wear) .......... .. .... (4) Replacement of friction
material not suggested or
required. Further inspection
required. See CALIPERS
and CALIPER HARDWARE.
Wear indicator device
(electronic) contacts
rotor .................. B ...... (5) Require replacement of
appropriate parts.
Wear indicator device
(mechanical) bent ....... .. .......... (6) Further inspection
required.
Wear indicator device
(mechanical) broken .... .. ......... (6) Further inspection
required.
Wear indicator device
(mechanical) contacts
rotor .................. .. ......... (6) Further inspection
required.
Worn close to minimum
specifications ......... 1 ........ (7) Suggest replacement.
Worn to, or below minimum
specifications ......... B ............ 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 ... 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.
Blistered ............... B ............ Require replacement.
Fitting threads damaged . A .. Require repair or replacement.
Fitting threads stripped
(threads missing) ...... A ............ Require replacement.
Incorrectly secured ..... B ................. Require repair.
Inner fabric
(webbing) cut .......... B ............ Require replacement.
Leaking ................. A ............ Require replacement.
Missing ................. C ............ Require replacement.
Outer covering is cracked
to the extent that
inner fabric of hose
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 ... 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.
Disabled ................ A .. Require repair or replacement.
Electrical failure ...... A .. Require repair or replacement.
External leak ........... A .. Require repair or replacement.
Housing cracked ......... B .. Require repair or replacement.
Inoperative (2) ......... A .. Require repair or replacement.
Internal leak ........... A .. Require repair or replacement.
Missing ................. C ............ Require 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.
Valve stuck ............. A .. Require repair or 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 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 .. Require repair or replacement.
Brake pedal drops
intermittently ......... A ........... (1) Require repair or
replacement.
Fluid level low ......... .. ......... (2) Further inspection
required.
Internal valve failure .. A .. Require repair or replacement.
Master cylinder leaking
brake fluid internally . A .. Require repair or replacement.
Piston does not return .. A .. Require repair or replacement.
Ports plugged ........... A .. Require repair or replacement.
Rubber master cylinder
cover gasket distorted
and gummy .............. A .. (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.