1993 Jeep Cherokee

GENERAL INFORMATION

Drivetrain/Transmission Motorist Assurance Program

Standards For Automotive Repair

All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

OVERVIEW OF MOTORIST ASSURANCE PROGRAM OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS

Drive/Power Train Assemblies

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES TRANSFER CASE ASSEMBLIES

Drive/Power Train Components

ACTUATORS (ELECTRICAL)

ACTUATORS (VACUUM)

AXLES

BEARINGS AND RACES

BELL CRANKS

BELL HOUSINGS

BUSHINGS (EXTERNAL)

CABLES (SPEEDOMETER)

CABLES (TV, DETENT AND SHIFT)

CARRIER BEARINGS

CLUTCH CABLES AND CABLE HOUSINGS

CLUTCH DISCS (MANUAL TRANSMISSION)

CLUTCH FORKS

CLUTCH LINKAGES (MECHANICAL)

CLUTCH MASTER CYLINDERS

CLUTCH PEDALS

CLUTCH PIVOTS

CLUTCH PRESSURE PLATES

CLUTCH RELEASE BEARINGS

CLUTCH SLAVE CYLINDERS (CONCENTRIC)

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

COMPANION FLANGES

CONNECTORS

COOLER BYPASS VALVES

COOLER LINES

COOLERS

CV JOINTS

DIP STICK TUBES

DIP STICKS (FLUID LEVEL INDICATORS)

DOWEL PINS, GUIDES AND PILOT HOLES

DRIVE SHAFT FLANGES

DRIVE SHAFTS AND HALF SHAFTS

DUST BOOTS

ENGINE MOUNTS

EXCITER RINGS

FILLER TUBES

FILTERS AND SCREENS

FLANGES

FLEX PLATES

FLUID LEVEL INDICATORS

FLUIDS AND LUBRICANTS

FLYWHEELS

FORCE MOTORS

GUIDES

HALF SHAFTS

HOSES, LINES AND TUBES

HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)

INTERMEDIATE SHAFT SUPPORT BEARINGS

KEY INTERLOCK SYSTEMS

LIMITED SLIPS

LINES

LINKAGES (EXTERNAL)

LOCKING HUB ASSEMBLIES

LOCKING HUB CONTROL KNOBS

LUBRICANTS

METAL-CLAD SEALS

METALASTIC JOINTS

MODULATOR PINS

MODULATORS

MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)

ODOMETER DRIVES (MECHANICAL)

ODOMETER HEADS (MECHANICAL)

OIL PANS

PANS

PILOT HOLES

PRESSURE PLATES

PRESSURE SWITCHES

RACES

RUBBER JOINTS (METALASTIC)

SCREENS

SEALS

SEALS (METAL-CLAD)

SELECTOR INTERLOCK SYSTEMS

SERVOS

SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)

SENSORS

SIDE COVERS

SLIP YOKES

SOLENOIDS

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

SPEEDOMETER-DRIVEN GEAR HOUSINGS

SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)

SPEEDOMETER/ODOMETER HEADS (MECHANICAL)

SPEEDOMETERS AND ODOMETERS (ELECTRONIC)

SWITCHES

TONE WHEELS

TOOTHED RINGS (TONE WHEELS)

TORQUE CONVERTERS

TRANSAXLE MOUNTS

TRANSDUCERS (TRANSMISSION)

TRANSMISSION COOLERS

TRANSMISSION MOUNTS

TRANSMISSION PANS

TRANSMISSION RANGE INDICATORS (PRNDL)

TUBES

UNIVERSAL JOINTS (CARDON OR CROSS TYPE)

VACUUM CONTROLS

VACUUM HOSES

VACUUM MOTORS

VACUUM-OPERATED SWITCHES

VEHICLE SPEED SENSORS

VENTS

VIBRATION DAMPERS

WHEEL ATTACHMENT HARDWARE

WHEEL SPEED SENSORS

WIRING HARNESSES AND CONNECTORS

YOKES AND SLIP YOKES

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 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 were recently published. Further, revisions to all of these inspection communication standards are continually republished. 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 & 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

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

performance) С - Part is missing

NOTE: When a repair is required, the shop must refuse partial service to the system in question, if the repair creates or continues an unsafe condition.

Reasons to Suggest Repair or Replacement

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

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

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

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

3 - To comply with maintenance recommended by the 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.

DRIVE/POWER TRAIN ASSEMBLIES

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER

VEHICLE OPERATION

NOTE: Whenever transmission or drivetrain service is performed that affects the suspension alignment, for example, removing the engine cradle, it is required that the alignment be checked and corrected if necessary.

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION

Condition

Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. (1)

Code

A

Procedure

Require repair or replacement of the differential assembly.

Code

Condition

Any internal component
failure that requires
removal of the assembly
from the vehicle for
service. (1)

Procedure

А ... Require repair or replacement

of the manual

transmission/transaxle

assembly.

refer to the component listing in this document.

TRANSFER CASE ASSEMBLIES

TRANSFER CASE ASSEMBLY INSPECTION

Condition

Code

Procedure

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted,

affecting performance .. A

Connector melted, not affecting performance .. 2

Connector missing C

Inoperative A

Missing C

Noisy 2

Out of adjustment B

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not affecting performance . . 1

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

(1) Suggest repair or

replacement.

Require replacement.

(2) Require replacement.

Require replacement.

Suggest repair or replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

(1) Suggest repair or

Terminal corroded,

affecting performance ... A Terminal corroded, not

affecting performance .. . 1 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

replacement.

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

ACTUATORS (VACUUM)

ACTUATOR (VACUUM) INSPECTION
Condition Code

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted,

affecting performance .. A

Connector melted, not affecting performance .. 2

Connector missing C

Inoperative A

Leaking (vacuum) A

Linkage bent, affecting

performance A

Linkage bent, not affecting performance . . 2

Linkage binding, affecting
performance A

Linkage binding, not affecting performance .. . 1

Linkage broken A

Linkage loose, affecting
performance A

Linkage loose, not affecting performance .. . 1

Procedure

Require repair or replacement of hardware.

Require replacement of

hardware.

Require repair or replacement

of hardware. Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

(1) Suggest repair or

replacement.

Require replacement.

.... (2) Require replacement. Require repair or replacement.

Require repair or replacement of linkage.

Suggest repair or replacement of linkage.

Require repair or replacement of linkage.

Suggest repair or replacement of linkage.

Require repair or replacement of linkage.

Require repair or replacement of linkage.

Suggest repair or replacement of linkage.

Linkage missing C

Linkage noisy 2

Missing C

Noisy 2

Out of adjustment A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Require replacement.

Suggest repair or replacement.
Require replacement.

Suggest repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.

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

Condition

Code

Procedure

Condition

Code

Procedure

Bearing end-play exceeds
specifications B

Require adjustment of bearing,

if possible. If proper

adjustment cannot be obtained,

require replacement of bearing

assembly.

feel rough when rotated as
an assembly B

Require replacement of bearing

assembly.

BELL CRANKS

BELL CRANK INSPECTION
Condition Code

Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Bent A

Broken A

Cracked A

Missing C

Worn, affecting

performance A

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require replacement.

Require repair or replacement.

BELL HOUSINGS

See HOUSINGS (BELL, CASE,

BUSHINGS (EXTERNAL)

BUSHING (EXTERNAL) INSPECTION

TAIL (EXTENSION) AND AUXILIARY)

Condition Code

Attaching hardware
bent B

Attaching hardware
broken A

Attaching hardware corroded, affecting structural integrity ... A

Attaching hardware
incorrect A

Attaching hardware
loose A

Attaching hardware
missing C

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.

Attaching hardware
threads damaged A

Attaching hardware threads
stripped (threads
missing) A

Require repair or replacement

of part with damaged threads if

available; otherwise, replace

bushing.

Require replacement of part

with stripped threads if

available; otherwise, replace

bushing.

Binding

Contaminated

Deteriorated, affecting

performance

Distorted, affecting

performance

Missing

Noisy

Rubber separating from
internal metal sleeve on
bonded bushing

Seized

Shifted (out of
position)

Split

Surface cracking (weather-
checked)

Worn, affecting

performance

Worn close to the end of

its useful life

A .. Require repair or replacement.

1 Suggest replacement.

A .. Require repair or replacement.

A .. Require repair or replacement.

A Require replacement.

2 (1) Further inspection

required.

A Require replacement.

A Require replacement.

В .. Require repair or replacement.

A Require replacement.

No service suggested or required.

A .. Require repair or replacement.
1 Suggest replacement.

Condition

Attaching hardware
broken

Attaching hardware
missing

Attaching hardware not
functioning A

Bent A

Binding A

Bracket bent, affecting
performance A

Bracket bent, not affecting performance

Procedure

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement. Require repair or replacement.

Require repair or replacement.
No service suggested or

Bracket broken, affecting
performance

Bracket broken, not affecting performance . .

Bracket corroded,

affecting performance .. . A Bracket corroded, not

affecting performance . . 2 Bracket cracked, affecting

performance A

Bracket cracked, not

affecting performance .. . 1 Bracket loose, affecting

performance A

Bracket loose, not

affecting performance .. . 1
Bracket missing C

Broken A

Cracked A

Disconnected A

Kinked A

Melted A

Missing C

Noisy 2

Routed incorrectly 2

Seized A

required. Require replacement.

No service suggested or required.

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

Suggest repair or replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or

replacement.
Require replacement.

Suggest repair or replacement.
Suggest repair.

Require repair or replacement.

Bracket corroded, not

affecting performance . . 2
Bracket cracked, affecting

performance A

Bracket cracked, not

affecting performance .. . 1
Bracket loose, affecting

performance A

Bracket loose, not

affecting performance .. . 1

Bracket missing C

Broken A

Cracked A

Disconnected A

Frayed A

Kinked A

Melted A

Missing C

Noisy 2

Out of adjustment B

Routed incorrectly 2

Seized A

Self-adjuster

inoperative A

Threads damaged A

Threads stripped (threads

missing) A

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

Suggest repair or replacement.

Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.
Require replacement.

Require repair or replacement.

(1) Require repair or

replacement.
Require replacement.

Suggest repair or replacement.

(2) Require repair or

replacement.
Suggest repair.

Require repair or replacement.

Require repair or replacement

of self-adjuster.

Require repair or replacement.

Require replacement.

CLUTCH DISCS (MANUAL TRANSMISSION)

CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION

Condition Code

Backing plate cracked

Broken

Contaminated with oil . . . Damper cushion broken ... Damper cushion

collapsed

Damper spring collapsed Damper spring missing .. Friction material cracked

through

Friction material flaking

or chunking

Friction material surface

cracking

Grooved

Ridged

Splines worn, affecting
performance

Warped

Wear exceeds
specifications (where
applicable)

Worn close to the end of
its useful life

Worn, affecting
performance

Procedure

A Require replacement.

A Require replacement.

A Require replacement.

A Require replacement.

A Require replacement.

A Require replacement.

С (1) Require replacement.

В Require replacement.

В Require replacement.

В No service suggested or

required.

В No service suggested or

required unless the pressure

plate or flywheel is being

resurfaced or replaced. In this

case, replacement of clutch

disc is required.

В No service suggested or

required unless the pressure

plate or flywheel is being

resurfaced or replaced. In this

case, replacement of clutch

disc is required.

A Require replacement.

A Require replacement.

В Require replacement.

1 Suggest replacement.

A Require replacement.

Code

Condition

Bent

Broken

Cracked

Worn close to the end of
its useful life

Worn, affecting
performance

Procedure

В Require replacement.

A .. Require repair or replacement.

В .. Require repair or replacement.

1 Suggest replacement.

A Require replacement.

CLUTCH LINKAGES (MECHANICAL)

See LINKAGES (EXTERNAL).

CLUTCH MASTER CYLINDERS

CLUTCH MASTER CYLINDER INSPECTION

Condition Code Procedure

Cover gasket distorted .. A .... Require replacement of cover

gasket.

Cover gasket gummy A .... Require replacement of cover

gasket. Cylinder leaking fluid

from rear of bore A .. Require repair or replacement.

Cylinder leaking fluid

internally A Require replacement.

Dust boot missing C Require replacement of dust

boot.

Dust boot punctured A Require replacement of dust

boot.

Dust boot torn A Require replacement of dust

boot.

Fluid level incorrect ... B . Require fluid level adjustment. Housing damaged, affecting

performance A . . Require repair or replacement.

Master cylinder has residue in reservoir (make parallel w/brakes

when they are done) .... 2 (1) Further inspection

required.

Threads damaged A Require repair replacement

Threads stripped (threads
missing) A Require replacement.

(1) - DO NOT replace master cylinder unless it exhibits

conditions listed for replacement. You may suggest fluid change according to OEM service intervals.

CLUTCH PEDALS

CLUTCH 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.

Pivot bushings worn,

affecting performance .. A .... Require replacement of pivot

bushings.

CLUTCH PIVOTS

CLUTCH PIVOT INSPECTION

Condition Code Procedure

Bent A Require replacement.

Broken A .. Require repair or replacement.

Cracked A .. Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Worn close to the end of

its useful life 1 Suggest replacement.

Worn, affecting

performance A Require replacement.

CLUTCH PRESSURE PLATES

See PRESSURE PLATES.

CLUTCH RELEASE BEARINGS

CLUTCH RELEASE BEARING INSPECTION

Condition Code Procedure

Collar broken A Require replacement.

Cracked A Require replacement.

Rough when rotated as an

assembly B Require replacement.

Seized A Require replacement.

Wear exceeds

specifications B Require replacement.

Worn close to the end of

its useful life 1 Suggest replacement.

Worn, affecting

performance A Require replacement.

CLUTCH SLAVE CYLINDERS (CONCENTRIC)

CLUTCH SLAVE CYLINDER (CONCENTRIC) INSPECTION

Condition Code Procedure

Bearing rough when rotated

as an assembly B Require replacement.

Bearing seized A Require replacement.

Bleeder pipe leaks A .. Require repair or replacement.

Carrier assembly worn,

affecting performance .. A Require replacement.

Collar broken A Require replacement.

Cracked A Require replacement.

Housing leaks A Require replacement.

Inoperative A Require replacement.

Release binding A Require replacement.

Spring broken A Require replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Worn, affecting

performance A Require replacement.

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

CLUTCH SLAVE CYLINDER (CONVENTIONAL OR EXTERNAL) INSPECTION
Condition Code Procedure

Binding A . . Require repair or replacement.

Bleeder port damaged (not

repairable) A (1) Require replacement.

Bleeder port damaged

(repairable) A (1) Require repair.

Bleeder screw broken off

in slave cylinder A (1) Require replacement.

Bleeder screw seized .... A (2) Require replacement.

Bore corroded (pitted) .. B Require replacement.

Bore grooved A Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

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 it has been made.

COMPANION FLANGES

See YOKES AND SLIP YOKES.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

COOLER BYPASS VALVES

COOLER BYPASS VALVE INSPECTION

Condition Code Procedure

Inoperative A Require replacement.

Installed incorrectly ... A Require repair.

Leaking A .. Require repair or replacement.

Restricted A .. Require repair or replacement.

COOLER LINES

COOLER LINE INSPECTION

Condition Code Procedure

Abrasion damage, affecting

structural integrity ... A .. Require repair or replacement. Abrasion damage, not

affecting structural

integrity No service suggested or

required.

Application incorrect ... B 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. Clamp corroded, not

reusable 1 Suggest replacement.

Connected incorrectly ... A Require repair.

Corroded, affecting

structural integrity ... A Require replacement.

Corroded, not affecting

structural integrity No service suggested or

required.

Cracked A . . Require repair or replacement.

Fitting type incorrect

(such as compression

fitting) B Require replacement.

Flange leaking A . . Require repair or replacement.

Insufficient clamping

force, allowing hose to

leak A . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Melted 1 .. Suggest repair or replacement.

Missing C Require replacement.

Outer covering damaged to

the extent that the inner

fabric is visible A Require replacement.

Protective sleeves

damaged 2 . Suggest replacement of sleeves.

Protective sleeves

missing C . Require replacement of sleeves.

Restricted, affecting

performance A . . Require repair or replacement.

Routed incorrectly 2 Require repair.

Swollen 1 Suggest replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Type incorrect 1 .. Suggest repair or replacement.

COOLERS

See TRANSMISSION COOLERS.

CV JOINTS

CV JOINT INSPECTION

Condition Code Procedure

Bearing, bushing or seal surface worn, affecting

performance A . . Require repair or replacement.

Boot clamp broken A ... Require repair or replacement

of c lamp.
Boot clamp loose A ... Require repair or replacement

of c lamp.
Boot clamp missing C ... Require repair or replacement

of c lamp.

Boot leaking A . Require replacement of CV boot.

Boot surface cracked,

Suggest replacement of CV boot.

Require repair or replacement

of CV joint.

Housing damaged to the
extent that it no longer
performs its intended
function A

(1) Require repair or replacement of CV joint.

Housing worn to the extent that it no longer performs its intended function .. A

А (1) Require repair or

Holes elongated

Internal parts binding Internal parts worn Lubricant missing

replacement of CV joint.

A Require replacement.

A .. Require repair or replacement. A .. Require repair or replacement. С ... Require cleaning, inspection, and repacking of CV joint. A .. Require repair or replacement.

Threads damaged

Threads stripped (threads
missing)

(1) - Housing assembly may appear blue in color from normal manufacturing process of heat-treating the housing.

DIP STICK TUBES

DIP STICK TUBE INSPECTION

Condition

Broken A

Checkball missing C

Cracked A

Hold down bracket

broken A

Hold down bracket

missing C

Leaking A

Missing C

Threads damaged A

Threads stripped (threads

missing) A

Procedure

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

Require repair or replacement.

Require replacement.

Require repair or replacement.
Require replacement.

Require repair or replacement.

Require replacement.

DIP STICKS (FLUID LEVEL INDICATORS)

DIP STICK (FLUID LEVEL INDICATOR) INSPECTION
Condition Code

Procedure

Application incorrect

Broken

Compressed

Missing

Modified

Stretched

В Require replacement.

A Require replacement.

A .. Require repair or replacement.

С Require replacement.

A Require replacement.

A .. Require repair or replacement.

Condition

Code

Procedure

Application incorrect ... B

Cracked A

Distorted A

Missing C

Positioned incorrectly . . R

Stepped A

Worn to the extent that it no longer performs its

intended function A

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement.

Condition

Balance weight missing .. R Bearing cap bore

distorted A

Bent A

Bolt holes elongated .... A Bushing or seal surface

worn, affecting

performance A

Leaking through soft yoke

plug A

Out of balance A

Retainer strap bent A

Slip yoke broken A

Splines worn, affecting

performance A

Splines worn close to

the end of their

useful life 1

Threads damaged A

Threads stripped (threads

missing) A

U-bolt damaged, affecting

performance A

Yoke damaged, affecting

performance A

Procedure Require repair or replacement.

Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement

of soft yoke plug.

Require repair or replacement.

Require replacement of

retainer strap.
Require replacement.

Require replacement.

Suggest replacement.

Require repair or replacement.

Require replacement.

Require replacement of U-bolts. Require repair or replacement.

Condition

Code

Procedure

Torn

A Require replacement.

Condition

Code

Procedure

At service interval 3 Suggest replacement.

A .. Require repair or replacement.

Bent

Exceeding service

interval

Missing

Near service interval
Restricted

Torn

Worn, affecting performance (metal or nylon screen type)

3 Suggest replacement.

С Require replacement.

3 Suggest replacement.

A (1) Require repair or

replacement.
A Require replacement.

А .. Require repair or replacement.

Code

Condition

Bent, affecting
performance

Bent, not affecting
performance

Bolt or stud holes

elongated

Broken

Cracked

Ring gear worn close
to the end of its
useful life

Ring gear worn to the extent that it no longer

Procedure

A Require replacement.

No service suggested or required.

В Require replacement.

A Require replacement.

A Require replacement.

1 Suggest replacement.

performs its intended

function A Require replacement.

Weights missing A Require replacement.

FLUID LEVEL INDICATORS

See DIP STICKS (FLUID LEVEL INDICATORS).

FLUIDS AND LUBRICANTS

FLUID AND LUBRICANT INSPECTION

Condition Code Procedure

Application incorrect ... B (1) Require replacement.

At service interval 3 Suggest replacement.

Beyond service interval . 3 Suggest replacement.

Burned (2) Further inspection

required. Contaminated, for example,

fluid other than hydraulic

fluid present A or B .... (3)(4) Require service.

Exceeding service

interval 3 Suggest replacement.

Hydraulic fluid

incorrect B (5) Require service.

Level incorrect B Require correction of fluid

level.

Near service interval ... 3 Suggest replacement.

Rubber master cylinder

cover gasket distorted

and gummy A (3) Require service.

Varnished (6) Further inspection

required.

3. - Determine and correct cause.

4. - Fluid that is burned indicates a serious problem.

Determine and correct the cause.

(3) - If a fluid other than hydraulic fluid is present in the

hydraulic system which DOES affect the rubber parts, the required service is to: 1) remove all components having rubber parts from the system, 2) flush lines with denatured alcohol or hydraulic cleaner, 3) repair or replace all components having rubber parts, and 4) bleed and flush with correct hydraulic fluid. (Code A)

(4) - If a fluid other than hydraulic fluid is present in the

hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct hydraulic fluid. (Code B)

(5) - If a fluid other than specification hydraulic fluid is

present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.

(6) - Fluid that is varnished may indicate a serious problem.

Determine and correct the cause.

FLYWHEELS

NOTE: Clutch disc replacement does not necessitate flywheel reconditioning, unless other conditions justify the reason to do so.

FLYWHEEL 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. Cracked (other than

mounting area) A (1) Require resurfacing or

replacement.

Cracks in mounting area . B Require replacement.

Hard spots B .. Require repair or replacement.

Ring gear broken A Require replacement of ring

gear. Ring gear teeth worn,

affecting performance .. A Require replacement of ring

gear. Runout exceeds

specifications B . . Require repair or replacement.

Scored B . . Require repair or replacement.

Surface cracks after

resurfacing to

manufacturer� s minimum

specifications B Require replacement.

Wear exceeds

specifications B Require replacement.

Worn close to the end of

its useful life 1 Suggest replacement.

Worn, affecting

performance A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Some manufacturers allow slight surface cracking in the friction surface.

FORCE MOTORS

See ACTUATORS (ELECTRICAL).

GUIDES

See DOWEL PINS, GUIDES AND PILOT HOLES.

HALF SHAFTS

See DRIVE SHAFTS AND HALF SHAFTS.

HOSES, LINES AND TUBES

HOSE, LINE AND TUBE INSPECTION

Condition Code Procedure

Application incorrect . . .

Connected incorrectly

Corroded, not reusable

Cracked

Dry-rotted

Hard

Inner fabric (webbing)
damaged

Insufficient clamping
force, allowing hose to
leak

Leaking

Maintenance intervals . . .

Melted

Missing

Outer covering damaged

Outer covering damaged to
the extent that the inner
fabric is visible

Protective sleeves
damaged

Protective sleeves

missing

Restricted, affecting
performance

Restricted, not affecting
performance

Routed incorrectly

Safety clip missing

Spongy

Stripped

Swollen

Threads damaged

Threads stripped (threads
missing)

Type incorrect

В Require replacement.

A Require repair.

1 Suggest replacement.

A Require replacement.

1 .. Suggest repair or replacement.

1 .. Suggest repair or replacement.

A Require replacement.

A .. Require repair or replacement.

A .. Require repair or replacement.

3 Suggest replacement.

1 .. Suggest repair or replacement.

С Require replacement.

1 Suggest replacement.

A Require replacement.

2 . Suggest replacement of sleeves.

2 . Suggest replacement of sleeves.

A .. Require repair or replacement.

2 .. Suggest repair or replacement.

2 Suggest replacement.

С Require replacement.

1 .. Suggest repair or replacement.

A Require replacement.

В Require replacement.

A .. Require repair or replacement.

A Require replacement.

1 .. Suggest repair or replacement.

Condition

Code

Procedure

Require replacement.

Require repair or replacement. (1) - See DOWEL PINS, GUIDES AND PILOT HOLES.

Bearing race loose

in bore A

Broken, affecting

performance A

Cracked A

Dowel pin holes worn,

affecting performance . . A

Machined surfaces damaged, affecting performance ... A

Threads damaged A

Threads stripped (threads
missing) A

Worn, affecting
performance A

Require repair or replacement.

Require repair or replacement. Require repair or replacement.

1) Require repair or replacement.

Require repair or replacement. Require repair or replacement.

INTERMEDIATE SHAFT SUPPORT BEARINGS

INTERMEDIATE SHAFT SUPPORT BEARING 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. Bearing rollers, balls or

races are worn, pitted,

noisy, or feel rough when

rotated as an assembly . A .. Require replacement of bearing

assembly. Bracket bent, affecting

performance A .. Require repair or replacement.

Bracket bent, not

affecting performance No service suggested or

required. Bracket broken, affecting

performance A Require replacement.

Bracket broken, not

affecting performance No service suggested or

required. Bracket corroded,

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

affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting

performance A . . Require repair or replacement.

Bracket cracked, not

affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,

affecting performance .. A .. Require repair or replacement. Bracket holes elongated,

not affecting

performances) No service suggested or

required. Bracket loose, affecting

performance A .. Require repair or replacement.

Bracket loose, not

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

Bracket missing C Require replacement.

Cracked Require replacement.

Rough (brinelling,

spalling) A Require replacement.

Rubber deteriorated,

affecting performance . . A Require replacement.

Seized A Require replacement.

KEY INTERLOCK SYSTEMS

See SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS) .

LIMITED SLIPS

See DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES.

LINES

See HOSES, LINES AND TUBES.

LINKAGES (EXTERNAL)

LINKAGE (EXTERNAL) INSPECTION

Condition Code Procedure

Components missing C .. Require replacement of missing

components. Linkage bent, affecting

performance A ... Require repair or replacement

of linkage. Linkage bent, not

affecting performance .. 2 ... Suggest repair or replacement

of linkage. Linkage binding, affecting

performance A ... Require repair or replacement

of linkage. Linkage binding, not

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

of linkage.

Linkage broken A ... Require repair or replacement

of linkage. Linkage loose, affecting

performance A ... Require repair or replacement

of linkage. Linkage loose, not

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

of linkage.

Linkage missing C Require replacement.

Linkage noisy 2 .. Suggest repair or replacement.

Out of adjustment B .. Require repair or replacement.

Worn to the extent that it
no longer performs its
intended function A .. Require repair or replacement.

LOCKING HUB ASSEMBLIES

LOCKING HUB ASSEMBLY INSPECTION

Condition Code Procedure

Inoperative A (1) Require repair or

replacement.

Loose A . . Require repair or replacement.

Seized in any position .. A .. Require repair or replacement.

(1) - Inoperative includes intermittent operation. LOCKING HUB CONTROL KNOBS

LOCKING HUB CONTROL KNOB INSPECTION

Condition Code Procedure

Damaged, affecting

performance A Require replacement.

Missing C Require replacement.

Worn, affecting

performance A Require replacement.

LUBRICANTS

See FLUIDS AND LUBRICANTS.

METAL-CLAD SEALS

See SEALS.

METALASTIC JOINTS

See RUBBER JOINTS (METALASTIC).

MODULATOR PINS

MODULATOR PIN INSPECTION

Condition Code Procedure

Application incorrect ... B Require replacement.

Missing C Require replacement.

MODULATORS

MODULATOR INSPECTION

Condition Code Procedure

Bent, affecting

performance A Require replacement.

Contaminated (water, fuel,

etc. ) A ( 1) Require replacement.

Housing cracked A Require replacement.

Inoperative A (2) Require replacement.

Leaking fluid

externally A .. Require repair or replacement.

Leaking fluid

internally A Require replacement.

Leaking vacuum A Require replacement.

Nipple broken A Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

(1) - Further inspection is required to determine the cause

of the contamination.

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

specification.

MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)

MOUNT (ENGINE, TRANSAXLE AND TRANSMISSION) 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 replacement.

Leaking (hydraulic

mount) A Require replacement.

Mounting hole worn,

affecting performance . . A Require replacement.

Mounting hole worn, not

affecting performance No service suggested or

required. Rubber deteriorated,

affecting performance . . A Require replacement.

Rubber deteriorated, not

affecting performance No service suggested or

required.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

ODOMETER DRIVES (MECHANICAL)

See SPEEDOMETER/ODOMETER DRIVES (MECHANICAL).

ODOMETER HEADS (MECHANICAL)

See SPEEDOMETER/ODOMETER HEADS (MECHANICAL).

OIL PANS

See TRANSMISSION PANS.

PANS

See TRANSMISSION PANS.

PILOT HOLES

See DOWEL PINS, GUIDES AND PILOT HOLES.

PRESSURE PLATES

PRESSURE PLATE INSPECTION

Condition Code Procedure

Balance weight missing .. C Require replacement.

Broken A Require replacement.

Contact surface

distorted B Require replacement.

Cracks B Require replacement.

Fingers bent A Require replacement.

Hard spots B Require replacement.

Scored B Require replacement.

Spring rate less than

specifications B Require replacement.

Worn, affecting

performance A Require replacement.

Worn beyond

specifications B Require replacement.

Worn close to the end of

its useful life 1 Suggest replacement.

PRESSURE SWITCHES

See SWITCHES.

RACES

See BEARINGS AND RACES.

RUBBER JOINTS (METALASTIC)

These joints may be found on half and/or drive shafts. They are usually found on European vehicles featuring a three-lug drive flange. They may be equipped with a centering ball or pin.

RUBBER JOINT (METALASTIC) INSPECTION

Condition Code Procedure

Drive flange bent A Require repair or

replacement. Drive flange damaged,

affecting performance .. A Require replacement.

Rubber drive joint

cracked 2 Suggest replacement.

Rubber drive joint

damaged, affecting

performance A Require replacement.

Rubber drive joint split

between mounting holes . A Require replacement.

Rubber drive joint torn at

mounting holes A Require replacement.

Rubber drive joint weather-
cracked No service suggested or

required.

SCREENS

See FILTERS AND SCREENS.

SEALS

SEAL INSPECTION

Condition Code Procedure

Leaking A ( 1) Require repair or

replacement.

(1) - Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged

vent may force fluid past the seal.

SEALS (METAL-CLAD)

See SEALS.

SELECTOR INTERLOCK SYSTEMS

See SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS) .

SERVOS

See ACTUATORS (VACUUM).

SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)

See:

ACTUATORS (ELECTRICAL)

CABLES

LINKAGES (EXTERNAL)

SWITCHES

SENSORS

SENSOR 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.

Inoperative A (2) Require repair or

replacement. Leaking

(vacuum/fluid/air) A Require replacement.

Out of adjustment B (3) Further inspection

required.

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.

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

replacement of part.

(2) - Inoperative includes intermittent operation or out of

specification.

(3) - Follow OEM recommended adjustment procedures. Repair

or replace if out of specification.

SIDE COVERS

See TRANSMISSION PANS.

SLIP YOKES

See YOKES AND SLIP YOKES.

SOLENOIDS

See:

ACTUATORS (ELECTRICAL)

ACTUATORS (VACUUM)

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

SPEED SENSOR (ELECTRONIC WHEEL AND VEHICLE) INSPECTION

Condition Code

Air gap incorrect B

Attaching hardware
missing C

Attaching hardware
threads damaged A

Attaching hardware threads stripped (threads missing)

Connector broken A

Connector (Weatherpack

type) leaking A

Connector melted A

Connector missing C

Contaminated A

Inoperative B

Leaking A

Loose A

Missing C

Resistance out of

Procedure

(1) Require adjustment or replacement.

Require replacement of hardware.

Require repair or replacement of hardware.

Require repair or replacement

of hardware.

Require repair or replacement.

Require repair or replacement.

(2) Require repair or

replacement.

Require replacement.

(3) Require repair or

replacement.

(4) Require repair or

replacement. Further

inspection required.

Require repair or replacement.

Require repair or replacement.

Require replacement.

specification B

Sensor housing cracked . . 2

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2
Terminal corroded,

affecting performance ... A
Terminal corroded, not

affecting performance .. 2
Terminal loose, affecting

performance B

Terminal loose, not

affecting performance .. . 1

Threads damaged A

Threads stripped (threads

missing) A

Wire lead conductors

exposed B

Wire lead corroded A

Wire lead misrouted B

Wire lead open A

Wire lead shorted A

Require repair or replacement.

Suggest replacement.

Require repair or replacement.

(2) Require repair or replacement.

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

Suggest repair or replacement. Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require re-routing according

to vehicle manufacturer�s

specifications.

Require repair or replacement. Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Worn close to the end of

its useful life 1 Suggest replacement.

Worn, affecting

performance A Require replacement.

(1) - Inoperative includes intermittent operation. SPEEDOMETER/ODOMETER HEADS (MECHANICAL)

SPEEDOMETER/ODOMETER HEAD (MECHANICAL) 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.

Lens broken A (1) Require repair or

replacement.

Lens cloudy 2 (1) Suggest repair or

replacement.

Lens missing C (1) Require repair or

replacement.

Malfunctioning A (2) Require repair or

replacement.

Noisy 2 . . Suggest repair or replacement.

Threads damaged A .. Require repair or replacement.

Threads stripped (threads
missing) A Require replacement.

(1) - If lens is available as a separate part, require

replacement of lens only.

(2) - Includes inoperative, intermittent operation, failure

to perform all functions, out of OEM specification, or out of range.

SPEEDOMETERS AND ODOMETERS (ELECTRONIC)

SPEEDOMETER AND ODOMETER (ELECTRONIC) 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.

Leaking A Require replacement.

Lens broken A (2) Require repair or

replacement.

Lens cloudy 2 (2) Suggest repair or

replacement.

Lens missing C (2) Require repair or

replacement.

Malfunctioning A (3) Require repair or

replacement. Mechanical head 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.

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

replacement of part.

(2) - If lens is available as a separate part, require

replacement of lens only.

(3) - Includes inoperative, intermittent operation, failure

to perform all functions, out of OEM specification, or out of range.

SWITCHES

SWITCH 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. Binding, affecting

performance A . . Require repair or replacement.

Binding, not affecting

performance 2 . . Suggest repair or replacement.

Broken A .. Require repair or replacement.

Burned, affecting

performance A (1) Require repair or

replacement.
Burned, not affecting
performance 2 (1) Suggest repair or

Cracked, affecting

performance A

Cracked, not affecting

performance 1

Leaking A

Malfunctioning A

Melted, affecting
performance A

Melted, not affecting
performance 2

Missing C

Out of adjustment B

Terminal broken A

Terminal burned, affecting

performance A

Terminal burned, not

affecting performance . . 2 Terminal corroded,

affecting performance .. . A Terminal corroded, not

affecting performance .. 2 Terminal loose, affecting

performance B

Terminal loose, not

affecting performance ... 1

Won�t return A

Worn 1

replacement. Require repair or replacement.

Suggest repair or replacement. Require repair or replacement.

(2) Require repair or

replacement.

1) Require repair or replacement.

(1) Suggest repair or

replacement.
Require replacement.

Require repair or replacement.

Require repair or replacement.

(1) Require repair or replacement.

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

Suggest repair or replacement.

Require repair or replacement.

Suggest replacement.

Condition

Code

Procedure

incorrect B

Teeth broken A

Teeth damaged, affecting

performance A

Require replacement. Require replacement.

Require replacement.

Condition

Converter clutch lock-up

operation is faulty .... A Cover shell damaged,

affecting performance .. A Does not meet stall speed

specification B

End play exceeds

specifications B

Hub broken A

Hub cracked A

Internal component

failure A

Leaking A

Pilot broken A

Pilot worn, affecting

performance A

Threads damaged A

Threads stripped (threads

missing) A

Weights missing C

Procedure

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require replacement.

Require repair or replacement.
Require replacement.

Require replacement.

Require repair or replacement.

Require replacement.

Require replacement.

Condition

Code

Procedure

Air flow obstruction .... A
Attaching hardware
broken A

Attaching hardware
missing C

Attaching hardware not
functioning A

Connection leaking A

Contaminated A

Corroded 1

Fins damaged, affecting

Require repair.

Require repair or replacement of hardware.

Require replacement of hardware.

Require repair or replacement of hardware.

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

performance A .. Require repair or replacement.

Fins damaged, not

affecting performance No service suggested or

required. Internal restrictions ... B . . Require repair or replacement.

Leaking A . . Require repair or replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A . . Require repair or replacement.

Tubes damaged, affecting

performance A .. Require repair or replacement.

Tubes damaged, not

affecting performance No service suggested or

required.

TRANSMISSION MOUNTS

See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) .

TRANSMISSION PANS

TRANSMISSION PAN INSPECTION

Condition

Code

Procedure

Bent, interfering with
filter or other internal
components A

Leaking A

Require repair or replacement. Require repair or replacement.

Code

Condition

Attaching hardware
broken

Procedure

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.

Bearing cap distorted ... B Require replacement.

Binding A Require replacement.

Cross (trunion) worn,

affecting performance .. A Require replacement.

Double cardon centering

ball damaged A Require replacement.

Double cardon centering

ball worn, affecting

performance A Require replacement.

Double cardon centering

spring broken A Require replacement.

Double cardon centering

spring missing C Require replacement.

Double cardon centering

spring weak A Require replacement.

End cap seal cracked .... 2 Suggest replacement.

End cap seal missing .... C .... Require replacement of seal.

Grease fitting broken ... A (1) Require replacement of

grease fitting.

Grease fitting missing .. C (2) Require replacement of

grease fitting. Rust-colored powder around

end cap seals A Require replacement.

Threads damaged A . . Require repair or replacement.

Threads stripped (threads

missing) A Require replacement.

Worn, affecting

performance A Require replacement.

(1) - A broken grease fitting does not require replacement

of the U-Joint.

(2) - A missing grease fitting does not require replacement

of the U-Joint.

VACUUM CONTROLS

See ACTUATORS (VACUUM).

VACUUM HOSES

See HOSES, LINES AND TUBES.

VACUUM MOTORS

See ACTUATORS (VACUUM).

VACUUM-OPERATED SWITCHES

See SWITCHES.

VEHICLE SPEED SENSORS

See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .

VENTS

VENT INSPECTION

Condition

Code

Procedure

Condition

Broken A

Missing C

Out of position B

Threads damaged A

Threads stripped (threads

missing) A

Procedure

Require replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require replacement.

Condition

Code

Procedure

WHEEL SPEED SENSORS

See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) .

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION

Condition Code Procedure

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

broken A ... Require repair or replacement

of hardware. Attaching hardware

missing C Require replacement of

hardware. Attaching hardware not

functioning A . . Require repair or replacement

of hardware.

Connector broken A .. Require repair or replacement.

Connector (Weatherpack

type) leaking A .. Require repair or replacement.

Connector melted A (1) Require repair or

replacement.

Connector missing C Require replacement.

Insulation damaged,

conductors exposed A .. Require repair or replacement.

Insulation damaged,

conductors not exposed . 1 Suggest replacement.

Open A . . Require repair or replacement.

Protective shield

(conduit) melted 2 (1) Suggest repair or

replacement. Protective shield

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

Resistance (voltage drop)

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

Routed incorrectly B Require repair.

Secured incorrectly B Require repair.

Shorted A . . Require repair or replacement.

Terminal broken A .. Require repair or replacement.

Terminal burned, affecting

performance A (1) Require repair or

replacement. Terminal burned, not

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

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

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

performance B . . Require repair or replacement.

Terminal loose, not

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

leaking See TRANSMISSION ASSEMBLY.

Voltage drop out of

specification A .. Require repair or replacement.

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

YOKES AND SLIP YOKES

YOKE AND SLIP YOKE INSPECTION
Condition Code

Bearing cap bore

distorted A

Bent A

Bolt holes elongated .... A Bushing or seal surface

worn, affecting

performance A

Leaking through soft yoke

plug A

Retainer strap bent A

Slip yoke broken A

Splines worn, affecting

performance A

Splines worn close

to the end of their

useful life 1

Threads damaged A

Threads stripped (threads

missing) A

U-bolt damaged, affecting

performance A

Yoke damaged, affecting
performance A

Procedure

Require repair or replacement.

Require replacement.

Require repair or replacement.

Require repair or replacement.

Require repair or replacement of soft yoke plug.

Require replacement of

retainer strap.
Require replacement.

Require replacement.

Suggest replacement.

Require repair or replacement.

Require replacement.

Require replacement

of U-bolts.

Require repair or replacement.