Contents Wiring diagrams Section: MAP Guidelines All sections

MAP - Drive Train & Transmission Jeep Grand Cherokee WK2

MAP Guidelines ~2186 words

DRIVE TRAIN & TRANSMISSION SYSTEMS

These materials are confidential and are not to be disclosed to, or utilized by, any individual or entity other than participants of the Motorist Assurance Program (MAP).

The Automotive Maintenance and Repair Association (AMRA) and MAP do not warrant these materials or guarantee their accuracy, and AMRA and MAP assume no liability for errors.

MAP STANDARDS OF SERVICE

MAP developed standards of service for shops to follow in working with customers. Written from the point of view of customers, and for the use of maintenance and repair shops, the standards expand on the ideas and promises established in MAP's Pledge to Customer

I. Our recommendations are based upon the following definitions.

System Failure - Parts/system indicated are out of manufacturers' specifications, have failed or are unable to perform their normal function as intended or designed by the manufacturers. Service/replacement is required.

Preventive/Scheduled Maintenance - Parts/system are scheduled for service/ replacement per industry standards or are near the end of their useful life and repair/ replacement is recommended in advance of parts/system failure. Service/replacement is suggested.

Improved System Performance - Parts/ system indicated are recommended for repair/ replacement to enhance/improve the vehicle's ability to perform as intended or designed by the manufacturer, or as requested by the customer. Service/replacement is suggested.

II. Training/Criteria Our personnel have acquired auto repair expertise through formal education or work experience. Where appropriate, personnel are moving toward certification (e.g. vehicle manufacturer, ASE, etc.) for the services performed. Continuing education will be supported by all MAP participants.

III. Appropriate Company Approved Inspection

We will perform an appropriate inspection based on MAP Uniform Inspection & Communication Standards.

IV. Written Estimates

Written estimates based on our inspection, in compliance with state and local regulations, will include parts (dollar amount), labor (dollar amount), and the total estimate.

V. Work Authorization

No work will be performed without the customer's prior approval.

VI. Limited Warranty

A minimum limited warranty will be offered of 90 days or 4,000 miles, whichever comes first, covering parts and labor.

VII. Returned Parts

All customers will be entitled to the return of old parts, or if they choose, they may examine the parts prior to leaving the store. Where failed parts are required to be returned to the manufacturer in order to honor the warranty, the customer will be allowed to examine the parts.

VIII. Classification of Parts

Replaced parts will be identified as new, remanufactured, rebuilt or used. MAP participants will inform the customer and indicate on the estimate and invoice whether a part is new, remanufactured, rebuilt or used.

THE MAP PROCESS - OVERVIEW

Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program comes 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, Electrical Systems, and Drive Train and Transmissions. Further, revisions to all of these inspection communication standards are continually re-published. 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.

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

201 Park Washington Court

Falls Church, Virginia 22046

Tel: (703) 532-2027 * Fax: (202) 318-0378

THE MAP PROCESS - OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-train, 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. However, any suggestions must be documented and must be based on substantial and informed experience or the vehicle manufacturer's recommended service interval. NOTE: Vehicle manufacturer service intervals are often categorized as either Normal or Severe. Frequently, motorists are unaware that their driving patterns and habits meet the criteria for following Severe Service schedules. Severe Service is generally defined as, but not limited to one or more of the following conditions: Driving in stop-and-go traffic; frequent short trips; high-speed driving; extreme temperatures; towing or hauling.

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.

  1. 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.
  2. 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.

  1. 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.
  2. 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.

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 ReplacementReasons to Suggest Repair or Replacement
Part no longer performs intended purpose Part does not meet a design specification (regardless of performance) Part is missingPart is close to the end of its useful life B - Part does not meet a design specification (regardless of performance) (just above discard specifications, or weak; failure likely to occur soon, etc.) To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.) To comply with maintenance recommended by the vehicle's Original Equipment Manufacturer (OEM) Technician's recommendation based on substantial and informed experience To comply with maintenance recommended by AMRA / MAP
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.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.
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.
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.

DRIVETRAIN AND TRANSMISSION

Note. When a procedure states that a required or suggested repair or replacement is recommended, the basis for the recommendation MUST be explained to the customer. If the customer asks whether there are alternatives to the recommendation, generally acceptable repair/replacement options must be explained, whether performed or not by the shop.

Note. Whenever transmission or drive-train 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.

Note. The conditions listed for the components included in this section assume that the problem has been isolated to the specific component through proper testing.

ACTUATORS (ELECTRICAL)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Require repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

ACTUATORS (VACUUM)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware.
Attaching hardware missingCRequire replacement of hardware.
Attaching hardware not functioningARequire repair or replacement of hardware.
Connector (Weatherpack type) leakingARequire repair or replacement.
Connector brokenARequire repair or replacement.
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
Leaking (vacuum)ARequire repair or replacement
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Suggest repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

AUTOMATIC TRANSMISSION / TRANSAXLE ASSEMBLIES/CVTS

ConditionCodeProcedure
Any internal component failure that requires removal of the assembly from the vehicle for service.ARequire repair or replacement of the automatic transmission / transaxle assembly.
NOTE: It is required that the torque converter and all other failure-related components be inspected for cause and condition. For components not requiring removal of the assembly, refer to the component listing
NOTE
It is required that the torque converter and all other failure-related components be inspected for cause and condition. For components not requiring removal of the assembly, refer to the component listing

AUTOMATIC TRANSMISSION FLUID

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct fluid.

AXLES

ConditionCodeProcedure
Bent, affecting performanceARequire replacement
Bent, beyond specificationBRequire repair or replacement
BrokenARequire replacement
End play exceeds specificationsBRequire repair or replacement
Flange bentARequire replacement
Flange threads strippedARequire repair or replacement
TwistedARequire replacement
Worn, affecting performanceARequire repair or replacement

BEARINGS AND RACES

Note. When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions that follow.

ConditionCodeProcedure
Bearing end-play exceeds specificationsBRequire adjustment of bearing, if possible
NOTE: If proper adjustment can't be obtained, require replacement of bearing assembly.
Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when rotated as an assemblyBRequire replacement of bearing assembly
NOTE
If proper adjustment can't be obtained, require replacement of bearing assembly.

BELL CRANKS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Bent, affecting performanceARequire repair or replacement
BrokenARequire repair or replacement
CrackedARequire repair or replacement
MissingCRequire replacement
Worn, affecting performanceARequire repair or replacement

BELL HOUSINGS

ConditionCodeProcedure
Bearing race loose in boreARequire repair or replacement
Broken, affecting performanceARequire repair or replacement
CrackedARequire repair or replacement
Dowel pin holes worn, affecting performanceSee Dowel Pins, Guides, and Pilot Holes
Leaking CoolantBRequire Repair or Replacement
NOTE: This condition is found mostly on Hybrid vehicles with a liquid cooled inverter.
Machined surfaces damaged, affecting performanceARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire repair or replacement
NOTE
This condition is found mostly on Hybrid vehicles with a liquid cooled inverter.

BUSHINGS (EXTERNAL)

ConditionCodeProcedure
Attaching hardware bentBRequire repair or replacement of bent part if available, otherwise, replace bushing
Attaching hardware brokenARequire repair or replacement of broken part if available, otherwise, replace bushing
Attaching hardware corroded, affecting structural IntegrityARequire repair or replacement of corroded part if available, otherwise, replace bushing
Attaching hardware incorrectBRequire repair or replacement of incorrect part if available, otherwise, replace bushing
Attaching hardware looseARequire repair or replacement of loose part if available, otherwise, replace bushing
Attaching hardware missingCRequire repair or replacement of missing part if available, otherwise, replace bushing
Attaching hardware threads damagedARequire repair or replacement of part with damaged threads if available, otherwise, replace bushing
Attaching hardware threads stripped (threads missing)ARequire repair or replacement of part with damaged threads if available, otherwise, replace bushing
BindingARequire repair or replacement
Contaminated1Suggest replacement
Deteriorated, affecting performanceARequire repair or replacement
Distorted, affecting performanceARequire repair or replacement
MissingCRequire replacement
Noisy2Further inspection required
NOTE: If noise isolated to bushing, suggest repair or replacement. Use only approved lubricant on rubber bushings. Petroleum-based lubricants may damage rubber bushings.
Rubber separating from internal metal sleeve on bonded bushingARequire replacement
SeizedARequire replacement
Shifted out of positionBRequire repair or replacement
SplitARequire replacement
Surface cracking (weather-checked)No service suggested or required
Worn affecting performanceARequire repair or replacement
Worn, close to the end of Its useful life1Suggest replacement
NOTE
If noise isolated to bushing, suggest repair or replacement. Use only approved lubricant on rubber bushings. Petroleum-based lubricants may damage rubber bushings.

CABLES (SPEEDOMETER)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BentARequire repair or replacement
BindingARequire repair or replacement
Bracket bent, affecting performanceARequire repair or replacement
Bracket bent, not affecting performance2Suggest repair or replacement of bracket
Bracket broken, affecting performanceARequire replacement
Bracket broken, not affecting performance2Suggest repair or replacement of bracket
Bracket corroded, affecting performanceARequire repair or replacement
Bracket cracked, affecting performanceARequire repair or replacement
Bracket cracked, not affecting performance1Suggest repair or replacement
Bracket loose, affecting performanceARequire repair or replacement
Bracket loose, not affecting performance1Suggest repair or replacement
Bracket missingCRequire replacement
BrokenARequire replacement
CrackedBRequire repair or replacement
DisconnectedARequire repair or replacement
KinkedARequire repair or replacement
MeltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
MissingCRequire replacement
Noisy2Suggest repair or replacement
Routed incorrectly, affecting performanceBRequire repair
SeizedARequire repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.

CABLES (TV, DETENT AND SHIFT)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BentARequire repair or replacement
BindingARequire repair or replacement

CARRIER BEARINGS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when rotated as an assemblyARequire replacement of bearing assembly
Bracket bent, affecting performanceARequire repair or replacement
Bracket bent, not affecting performanceNo service suggested or required
Bracket broken, affecting performanceARequire replacement
Bracket broken, not affecting performance2Suggest repair or replacement of bracket
Bracket corroded, affecting performanceARequire repair or replacement
Bracket corroded, not affecting performance2Suggest repair or replacement
Bracket cracked, affecting performanceARequire repair or replacement
Bracket cracked, not affecting performance1Suggest repair or replacement
Bracket holes elongated, affecting performanceARequire repair or replacement
Bracket holes elongated, not affecting performanceNo service suggested or required
Bracket loose, affecting performanceARequire repair or replacement
Bracket loose, not affecting performance1Suggest repair or replacement
Bracket missingCRequire replacement
CrackedBRequire replacement
Rough (brinelling, spalling)ARequire replacement
Rubber deteriorated, affecting performanceARequire replacement
SeizedARequire replacement

CLUTCH CABLES AND CABLE HOUSINGS

ConditionCodeProcedure
BrokenARequire replacement
Cable bentARequire replacement
Cable bindingARequire repair or replacement
Cable mounting looseBRequire repair or replacement
Cable out of adjustmentBRequire repair or replacement
FrayedBRequire replacement
Housing heat -damaged1Suggest replacement
MissingCRequire replacement
Noisy2Suggest repair or replacement
SeizedARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire replacement

CLUTCH DISCS (MANUAL TRANSMISSIONS)

ConditionCodeProcedure
Backing plate crackedBRequire replacement
BrokenARequire replacement
Contaminated with oilARequire replacement
NOTE: Determine source of oil and correct prior to repair or replacement of clutch disc.
Damper cushion brokenARequire replacement
Damper cushion collapsedARequire replacement
Damper spring collapsedARequire replacement
Damper spring missingCRequire replacement
NOTE: Not all clutch discs have springs in all spring chambers on the disc.
Friction material cracked throughBRequire replacement
Friction material flaking or chunkingBRequire replacement
Friction material surface crackingNo service suggested or required
GroovedBNo service suggested or required unless the pressure plate or flywheel is being resurfaced or replaced. In this case, replacement of clutch disc is required
RidgedBNo service suggested or required unless the pressure plate or flywheel is being resurfaced or replaced. In this case, replacement of clutch disc is required
Splines worn, affecting performanceARequire replacement
Warped, affecting performance.ARequire replacement
Wear exceeds specifications (where applicable)BRequire replacement
Worn, affecting performanceARequire replacement
Worn, not affecting performance yet close to the end of its useful life1Suggest replacement
NOTE
Determine source of oil and correct prior to repair or replacement of clutch disc.
NOTE
Not all clutch discs have springs in all spring chambers on the disc.

CLUTCH FORKS

ConditionCodeProcedure
Bent, affecting performanceBRequire replacement
BrokenARequire repair or replacement
CrackedBRequire repair or replacement
Worn, affecting performanceARequire replacement
Worn, not affecting performance yet close to the end of its useful life1Suggest replacement

CLUTCH LINKAGES (MECHANICAL)

ConditionCodeProcedure
Components missingCRequire replacement of missing components
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Suggest repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Worn to the extent that it no longer performs its intended functionARequire repair or replacement

CLUTCH MASTER CYLINDERS

ConditionCodeProcedure
Cover gasket distortedARequire replacement of cover gasket
Cover gasket gummyARequire replacement of cover gasket
NOTE: This condition may indicate contaminated fluid. Further inspection required.
Cylinder leaking fluid from rear of boreARequire repair or replacement
Cylinder leaking fluid internallyARequire replacement
Dust boot missingCRequire replacement of dust boot
Dust boot puncturedARequire replacement of dust boot
Dust boot tornARequire replacement of dust boot
Fluid level incorrectBRequire fluid level adjustment
Housing damaged, affecting performanceARequire repair or replacement
Master cylinder has residue in reservoir2Further inspection required
NOTE: Do not replace master cylinder unless it exhibits conditions listed for replacement.
Pushrod out of adjustmentBRequire Repair or Replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
This condition may indicate contaminated fluid. Further inspection required.
NOTE
Do not replace master cylinder unless it exhibits conditions listed for replacement.

CLUTCH PEDALS

ConditionCodeProcedure
Bent, affecting performanceARequire repair or replacement
Bent, not affecting performance2Suggest repair or replacement
BrokenARequire repair or replacement
Pedal pad missingCRequire replacement of pedal pad
Pivot bushings worn, affecting performanceARequire replacement of pivot bushings

CLUTCH PIVOTS

ConditionCodeProcedure
Bent, affecting performanceARequire replacement
BrokenARequire repair or replacement
CrackedBRequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire replacement
Worn, not affecting performance, but close to the end of its useful life2Suggest replacement

CLUTCH PRESSURE PLATES

ConditionCodeProcedure
Balance weight missingCRequire replacement
BrokenARequire replacement
Contact surface distortedBRequire replacement
CracksBRequire replacement
Fingers bentARequire replacement
Hard spotsBRequire replacement
ScoredBRequire replacement
Spring rate less than specificationsBRequire replacement
Worn beyond specificationsBRequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement

CLUTCH RELEASE BEARINGS

ConditionCodeProcedure
Collar brokenARequire replacement
CrackedBRequire replacement
Rough when rotated as an assemblyBRequire replacement
SeizedARequire replacement
Wear exceeds specificationsBRequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement

CLUTCH SLAVE CYLINDERS (CONCENTRIC)

ConditionCodeProcedure
Bearing rough when rotated as an assemblyBRequire replacement
Bearing seizedARequire replacement
Bleeder pipe leaksARequire repair or replacement
Carrier assembly worn, affecting performanceARequire replacement
Collar brokenARequire replacement
CrackedBRequire replacement
Housing leaksARequire replacement
InoperativeARequire replacement
Release bindingARequire replacement
Spring brokenARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire replacement

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

ConditionCodeProcedure
BindingARequire repair or replacement
Bleeder port damaged (not repairable)ARequire replacement
NOTE: Only required if the hydraulic system must be opened.
Bleeder port damaged (repairable)ARequire repair
NOTE: Only required if the hydraulic system must be opened.
Bleeder screw broken off in slave cylinderARequire replacement
NOTE: Only required if the hydraulic system must be opened.
Bleeder screw seizedARequire replacement
NOTE: Seized is defined as a bleeder screw that cannot be removed after a practical attempt at removing it has been made. Only required if the hydraulic system must be opened.
Bore corroded (pitted)BRequire replacement
Bore groovedARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Only required if the hydraulic system must be opened.
NOTE
Only required if the hydraulic system must be opened.
NOTE
Only required if the hydraulic system must be opened.
NOTE
Seized is defined as a bleeder screw that cannot be removed after a practical attempt at removing it has been made. Only required if the hydraulic system must be opened.

COMPANION FLANGES

ConditionCodeProcedure
Bearing cap bore distortedARequire repair or replacement
Bent, affecting performanceARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn close to the end of their useful life1Suggest replacement
Splines worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement

CONNECTORS

ConditionCodeProcedure
Application incorrectBRequire repair or replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
Insulation damaged, conductors exposedARequire repair or replacement
Insulation damaged, conductors not exposed1Suggest replacement
OpenARequire repair or replacement
Protective shield (conduit) melted2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Protective shield (conduit) missingCSuggest repair or replacement
Resistance (voltage drop) out of specificationARequire repair or replacement
Routed incorrectlyBRequire repair
Secured incorrectlyBRequire repair
ShortedARequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Transmission connector leakingSee Transmission Assembly
Voltage drop out of specificationARequire repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

COOLER BYPASS VALVES

ConditionCodeProcedure
InoperativeARequire replacement
Installed incorrectlyARequire repair
LeakingARequire repair or replacement
RestrictedARequire repair or replacement

COOLER LINES

ConditionCodeProcedure
Abrasion damage, affecting structural integrityARequire repair or replacement
Abrasion damage, not affecting structural integrityNo service suggested or required
Application incorrectBRequire replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Clamp corroded, not reusable1Suggest replacement
NOTE: If clamp removed, require replacement.
Connected incorrectlyARequire repair
Corroded, affecting structural integrityARequire replacement
Corroded, not affecting structural integrityNo service suggested or required
CrackedBRequire repair or replacement
Fitting type incorrect (such as compression fitting)BRequire replacement
Flange leakingARequire repair or replacement
Insufficient clamping force, allowing hose to leakARequire repair or replacement
LeakingARequire repair or replacement
Melted1Suggest repair or replacement
MissingCRequire replacement
Outer covering damaged to the extent that the inner fabric is visibleARequire replacement
Protective sleeves damaged2Suggest replacement of sleeves
Protective sleeves missingCRequire replacement of sleeves
Restricted, affecting performanceARequire repair or replacement
Routed incorrectlyBRequire repair
Swollen1Suggest replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Type incorrect2Suggest repair or replacement
NOTE
If clamp removed, require replacement.

COOLERS

ConditionCodeProcedure
Air flow obstructionARequire repair
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connection leakingARequire repair or replacement
ContaminatedARequire repair or replacement
Corroded1Suggest repair or replacement
Fins damaged, affecting performanceARequire repair or replacement
Fins damaged, not affecting performanceNo service suggested or required
Internal restrictionsBRequire repair or replacement
LeakingARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire repair or replacement
Tubes damaged, affecting performanceARequire repair or replacement
Tubes damaged, not affecting performanceNo service suggested or required

CV JOINTS

ConditionCodeProcedure
Bearing, bushing or seal surface worn, affecting performanceARequire repair or replacement
Boot clamp brokenARequire repair or replacement of clamp
Boot clamp looseARequire repair or replacement of clamp
Boot clamp missingCRequire repair or replacement of clamp
Boot leakingARequire replacement of CV boot
NOTE: Further inspection of joint required before replacing boot.
Boot surface cracked, not leaking2Suggest replacement of CV boot
Cage brokenARequire repair or replacement of CV joint
Housing damaged to the extent that it no longer performs its intended functionARequire repair or replacement of CV joint
NOTE: Housing assembly may appear blue in color from normal manufacturing process of heat treating the housing.
Housing worn to the extent that it no longer performs its intended functionARequire repair or replacement
NOTE: Housing assembly may appear blue in color from normal manufacturing process of heat treating the housing.
Internal parts bindingARequire repair or replacement
Internal parts wornARequire repair or replacement
Lubricant missingCRequire cleaning, inspection, and repacking of CV joint
Mounting holes elongatedARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Further inspection of joint required before replacing boot.
NOTE
Housing assembly may appear blue in color from normal manufacturing process of heat treating the housing.
NOTE
Housing assembly may appear blue in color from normal manufacturing process of heat treating the housing.

DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES

Note. Does not include half shafts.

ConditionCodeProcedure
Any internal component failure that requires removal of the assembly from the vehicle for service.ARequire repair or replacement of the differential assembly
NOTE: For components not requiring removal of the assembly, refer to the component listing.
NOTE
For components not requiring removal of the assembly, refer to the component listing.

DIFFERENTIAL FLUID

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Rubber master/ clutch cylinder cover gasket distorted or gummyARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.

DIP STICK TUBES

ConditionCodeProcedure
BrokenARequire repair or replacement
Check ball missingCRequire repair or replacement
CrackedBRequire repair or replacement
Hold down bracket brokenARequire repair or replacement
Hold down bracket missingCRequire replacement
LeakingBRequire repair or replacement
MissingCRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

DIP STICKS (FLUID LEVEL INDICATORS)

ConditionCodeProcedure
Application incorrectBRequire replacement
BrokenARequire replacement
CompressedARequire repair or replacement
MissingCRequire replacement
ModifiedARequire replacement
StretchedARequire repair or replacement

DOWEL PINS, GUIDES AND PILOT HOLES

ConditionCodeProcedure
Application incorrectBRequire repair or replacement
CrackedARequire repair or replacement
DistortedARequire repair or replacement
MissingCRequire replacement
Positioned incorrectlyBRequire repair or replacement
SteppedARequire repair or replacement
Worn to the extent that it no longer performs its intended functionARequire repair or replacement

DRAIN PLUGS AND GASKETS

ConditionCodeProcedure
LeakingARequire repair or replacement
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary.
MissingCRequire replacement
Threads DamagedARequire repair or replacement
NOTE
Require inspection of mating and sealing surface and repair or replace as necessary.

DRIVE SHAFT FLANGES

ConditionCodeProcedure
Bearing cap bore distortedARequire repair or replacement
Bent, affecting performanceARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn close to the end of their useful life1Suggest replacement
Splines worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement

DRIVE SHAFTS AND HALF SHAFTS

ConditionCodeProcedure
Balance weight missingCRequire repair or replacement
Bearing cap bore distortedARequire repair or replacement
BentARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke
Out of balanceARequire repair or replacement
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn, affecting performanceARequire repair or replacement
Splines worn, not affecting performance, but close to the end of their useful life1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement of Yoke

DUST BOOTS

ConditionCodeProcedure
Cracked, not leaking1Suggest replacement
LeakingARequire repair or replacement
MissingCRequire replacement
TornARequire replacement
Weather checked, surface crackedNo service suggested or required

ENGINE MOUNTS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BrokenARequire replacement
Leaking (hydraulic mount)ARequire replacement
Mounting hole worn, affecting performanceARequire replacement
Mounting hole worn, not affecting performanceNo service suggested or required
Rubber deteriorated, affecting performanceARequire replacement
Rubber deteriorated, not affecting performanceNo service suggested or required
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

EXCITER RINGS

ConditionCodeProcedure
Alignment incorrectBRequire repair or replacement
BentBRequire replacement
Contaminated, affecting performanceARequire repair. Identify and correct cause
CrackedBRequire replacement
LooseARequire replacement of worn parts
MissingCRequire replacement
Number of teeth incorrectBRequire replacement
Teeth brokenARequire replacement
Teeth damaged, affecting performanceARequire replacement

FILLER TUBES

ConditionCodeProcedure
BrokenARequire repair or replacement
Check ball missingCRequire repair or replacement
CrackedBRequire repair or replacement
Hold down bracket brokenARequire repair or replacement
Hold down bracket missingCRequire replacement
LeakingARequire repair or replacement
MissingCRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

FILTERS AND SCREENS

ConditionCodeProcedure
At service interval3Suggest replacement
Bent, affecting performanceARequire repair or replacement
Exceeding service interval3Suggest replacement
MissingCRequire replacement
Near service interval3Suggest replacement
RestrictedARequire repair or replacement
NOTE: Further inspection may be required to determine the source of restriction or contamination.
TornARequire replacement
Worn, affecting performance (metal or nylon screen type)ARequire repair or replacement
NOTE
Further inspection may be required to determine the source of restriction or contamination.

FLANGES

ConditionCodeProcedure
Bearing cap bore distortedARequire repair or replacement
Bent, affecting performanceARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn close to the end of their useful life1Suggest replacement
Splines worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement

FLEX PLATES

ConditionCodeProcedure
Bent, affecting performanceARequire replacement
Bent, not affecting performanceNo service suggested or required
Bolt or stud holes elongatedBRequire replacement
BrokenARequire replacement
CrackedBRequire replacement
Ring gear worn close to the end of its useful life1Suggest replacement
Ring gear worn to the extent that it no longer performs its intended functionARequire replacement
Weights missingARequire repair or replacement

FLUID LEVEL INDICATORS

ConditionCodeProcedure
Application incorrectBRequire replacement
BrokenARequire replacement
CompressedARequire repair or replacement
MissingCRequire replacement
ModifiedARequire replacement
StretchedARequire repair or replacement

FLUIDS AND LUBRICANTS

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Rubber master/ clutch cylinder cover gasket distorted or gummyARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.

FLYWHEELS

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

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Cracked (other than mounting area)ARequire repair or replacement of hardware
NOTE: Some manufacturers allow slight surface cracking in the friction surface.
Cracks in mounting areaBRequire replacement
Hard spotsBRequire repair or replacement
Ring gear teeth worn, affecting performanceARequire replacement of ring gear
Runout exceeds specificationsBRequire repair or replacement
ScoredBRequire repair or replacement
Surface cracks after resurfacing to manufacturer's minimum specificationsBRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Wear exceeds specificationsBRequire replacement
Worn, affecting performanceARequire repair or replacement
Worn, not affecting performance, but close to the end of its useful life1Suggest repair or replacement
NOTE
Some manufacturers allow slight surface cracking in the friction surface.

FORCE MOTORS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance1Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

GASKETS

ConditionCodeProcedure
LeakingARequire repair or replacement
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary.
NOTE
Require inspection of mating and sealing surface and repair or replace as necessary.

GUIDES

ConditionCodeProcedure
Application incorrectBRequire repair or replacement
CrackedARequire repair or replacement
DistortedARequire repair or replacement
MissingCRequire replacement
Positioned incorrectlyBRequire repair or replacement
SteppedARequire repair or replacement
Worn to the extent that it no longer performs its intended functionARequire repair or replacement

HALF SHAFTS

ConditionCodeProcedure
Balance weight missingCRequire repair or replacement
Bearing cap bore distortedARequire repair or replacement
BentARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Out of balanceARequire repair or replacement
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn, affecting performanceARequire repair or replacement
Splines worn, not affecting performance, but close to the end of their useful life1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement of yoke

HOSES, LINES, AND TUBES

ConditionCodeProcedure
Application incorrectBRequire replacement
At or beyond service interval3Suggest replacement
Connected incorrectlyARequire repair
Corroded, not reusable1Suggest replacement
Cracked line or tubeARequire replacement
Hard hose1Suggest replacement
Inner fabric (webbing) damagedARequire replacement
Insufficient clamping force, allowing hose to leakARequire repair or replacement
LeakingARequire repair or replacement
Melted1Suggest repair or replacement
MissingCRequire replacement
Outer covering damaged1Suggest replacement
Outer covering damaged to the extent that the inner fabric is visibleARequire replacement
Protective sleeves damaged2Suggest replacement of sleeves
Protective sleeves missing2Suggest replacement of sleeves
Restricted, affecting performanceARequire repair or replacement
Restricted, not affecting performance2Suggest repair or replacement
Routed incorrectly2Suggest replacement
Safety clip missingCRequire replacement
Spongy1Suggest repair or replacement
StrippedARequire replacement
Surface cracked (weather-checked)1Suggest repair or replacement
SwollenBRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Type incorrect1Suggest repair or replacement

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

ConditionCodeProcedure
Bearing race loose in boreARequire repair or replacement
Broken, affecting performanceARequire repair or replacement
CrackedBRequire repair or replacement
Dowel pin holes worn, affecting performanceARequire repair or replacement
Machined surfaces damaged, affecting performanceARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire repair or replacement

HYDRAULIC FLUID

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Rubber master/ clutch cylinder cover gasket distorted or gummyARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.

INTERMEDIATE SHAFT SUPPORT BEARINGS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when rotated as an assemblyARequire replacement of bearing assembly
Bracket bent, affecting performanceARequire repair or replacement
Bracket bent, not affecting performanceNo service suggested or required
Bracket broken, affecting performanceARequire replacement
Bracket broken, not affecting performance2Suggest repair or replacement of bracket
Bracket corroded, affecting performanceARequire repair or replacement
Bracket corroded, not affecting performance2Suggest repair or replacement
Bracket cracked, affecting performanceARequire repair or replacement
Bracket cracked, not affecting performance1Suggest repair or replacement
Bracket holes elongated, affecting performanceARequire repair or replacement
Bracket holes elongated, not affecting performanceNo service suggested or required
Bracket loose, affecting performanceARequire repair or replacement
Bracket loose, not affecting performance1Suggest repair or replacement
Bracket missingCRequire replacement
CrackedBRequire replacement
Rough (brinelling, spalling)ARequire replacement
Rubber deteriorated, affecting performanceARequire replacement
SeizedARequire replacement

KEY INTERLOCK SYSTEMS

Note. See: Actuators (Electrical), Cables, Linkages (External), Switches

LIMITED SLIPS

ConditionCodeProcedure
Any internal component failure that requires removal of the assembly from the vehicle for service.ARequire repair or replacement of the differential assembly.
NOTE: For components not requiring removal of the assembly, refer to the component listing.
NOTE
For components not requiring removal of the assembly, refer to the component listing.

LINES

ConditionCodeProcedure
Application incorrectBRequire replacement
At or beyond service interval3Suggest replacement
Connected incorrectlyARequire repair
Corroded, not reusable1Suggest replacement
Cracked line or tubeARequire replacement
Hard hose1Suggest replacement
Inner fabric (webbing) damagedARequire replacement
Insufficient clamping force, allowing hose to leakARequire repair or replacement
LeakingARequire repair or replacement
Melted1Suggest repair or replacement
MissingCRequire replacement
Outer covering damaged1Suggest replacement
Outer covering damaged to the extent that the inner fabric is visibleARequire replacement
Protective sleeves damaged2Suggest replacement of sleeves
Protective sleeves missingCSuggest replacement of sleeves
Restricted, affecting performanceARequire repair or replacement
Restricted, not affecting performance2Suggest repair or replacement
Routed incorrectlyBSuggest replacement
Safety clip missingCRequire replacement
Spongy1Suggest repair or replacement
StrippedARequire replacement
Surface cracked (weather-checked)ISuggest repair or replacement
SwollenBRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Type incorrect2Suggest repair or replacement

LINKAGES (EXTERNAL)

ConditionCodeProcedure
Components missingCRequire replacement of missing components
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Suggest repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Worn to the extent that it no longer performs its intended functionARequire repair or replacement

LOCKING HUB ASSEMBLIES

ConditionCodeProcedure
InoperativeARequire repair or replacement
NOTE: Inoperative includes intermittent operation.
LooseBRequire repair or replacement
Seized in any positionARequire repair or replacement
NOTE
Inoperative includes intermittent operation.

LOCKING HUB CONTROL KNOBS

ConditionCodeProcedure
Damaged, affecting performanceARequire replacement
MissingCRequire replacement
Worn, affecting performanceARequire replacement

LUBRICANTS

ConditionCodeProcedure
Additive DepletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
At service interval3Suggest replacement
Beyond service interval3Suggest replacement
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correctly specified hydraulic fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
Near service interval3Suggest replacement
OxidizedARequire replacement of fluid
Rubber master cylinder cover gasket distorted and gummyARequire service
NOTE: If a fluid other than brake fluid is present in the 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correctly specified hydraulic fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If a fluid other than brake fluid is present in the 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.

MANUAL TRANSMISSION FLUID

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Rubber master/ clutch cylinder cover gasket distorted or gummyARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.

MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES

ConditionCodeProcedure
Any internal component failure that requires removal of the assembly from the vehicle for service.ARequire repair or replacement of the manual transmission / transaxle assembly.
NOTE: For components not requiring removal of the assembly, refer to the component listing.
NOTE
For components not requiring removal of the assembly, refer to the component listing.

METAL CLAD SEALS

ConditionCodeProcedure
LeakingARequire repair or replacement
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.
NOTE
Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.

METALASTIC JOINTS

Note. 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.

ConditionCodeProcedure
Drive flange bentARequire replacement
Drive flange damaged, affecting performanceARequire replacement
Rubber drive joint cracked2Suggest replacement
Rubber drive joint damaged, affecting performanceARequire replacement
Rubber drive joint split between mounting holesARequire replacement
Rubber drive joint torn at mounting holesARequire replacement
Rubber drive joint weather-crackedNo service suggested or required

MODULATOR PINS

ConditionCodeProcedure
Application incorrectBRequire replacement
MissingCRequire replacement

MODULATORS

ConditionCodeProcedure
Bent, affecting performanceARequire replacement
Contaminated (water, fuel, etc. )ARequire replacement
NOTE: Further inspection is required to determine the cause of the contamination.
Housing crackedARequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
Leaking fluid externallyARequire repair or replacement
Leaking fluid internallyARequire replacement
Leaking vacuumARequire replacement
Nipple brokenARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Further inspection is required to determine the cause of the contamination.
NOTE
Inoperative includes intermittent operation.

MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BrokenARequire replacement
Leaking (hydraulic mount)ARequire replacement
Mounting hole worn, affecting performanceARequire replacement
Mounting hole worn, not affecting performanceNo service suggested or required
Rubber deteriorated, affecting performanceARequire replacement
Rubber deteriorated, not affecting performanceNo service suggested or required
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

ODOMETER DRIVES (MECHANICAL)

ConditionCodeProcedure
Application incorrectBRequire replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
LeakingBRequire repair or replacement
MissingCRequire replacement
Teeth brokenARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement
NOTE
Inoperative includes intermittent operation.

ODOMETER HEADS (MECHANICAL)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Lens brokenARequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only.
Lens cloudy2Suggest repair or replacement
NOTE: If lens is available as a separate part, suggest replacement of lens only.
Lens missingCRequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only.
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.
Noisy2Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
If lens is available as a separate part, require replacement of lens only.
NOTE
If lens is available as a separate part, suggest replacement of lens only.
NOTE
If lens is available as a separate part, require replacement of lens only.
NOTE
Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.

OIL PANS

ConditionCodeProcedure
Bent, interfering with filter or other internal componentsARequire repair or replacement
LeakingARequire repair or replacement

PANS

ConditionCodeProcedure
Bent, interfering with filter or other internal componentsARequire repair or replacement
LeakingARequire repair or replacement

PILOT HOLES

ConditionCodeProcedure
Application incorrectBRequire repair or replacement
CrackedARequire repair or replacement
DistortedARequire repair or replacement
MissingCRequire replacement
Positioned incorrectlyBRequire repair or replacement
SteppedARequire repair or replacement
Worn to the extent that it no longer performs its intended functionARequire repair or replacement

PRESSURE PLATES

ConditionCodeProcedure
Balance weight missingCRequire replacement
BrokenARequire replacement
Contact surface distortedBRequire replacement
CracksBRequire replacement
Fingers bentARequire replacement
Hard spotsBRequire replacement
ScoredBRequire replacement
Spring rate less than specificationsBRequire replacement
Worn beyond specificationsBRequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement

PRESSURE SWITCHES

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Binding, affecting performanceARequire repair or replacement
Binding, not affecting performance2Suggest repair or replacement
BrokenARequire repair or replacement
Burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Cracked, affecting performanceARequire repair or replacement
Cracked, not affecting performance1Suggest repair or replacement
LeakingBRequire repair or replacement
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, or failure to perform all functions.
Melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
MissingCRequire replacement
Out of adjustmentBRequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Won't returnARequire repair or replacement
Worn1Suggest replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Includes inoperative, intermittent operation, or failure to perform all functions.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

RACES

Note. When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions that follow.

ConditionCodeProcedure
Bearing end-play exceeds specificationsBRequire adjustment of bearing, if possible If proper adjustment cannot be obtained, require replacement of bearing assembly
NOTE: When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions
Bearing rollers, balls or races are worn, pitted, or feel rough when rotated as an assemblyBRequire replacement of bearing assembly
NOTE: When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions
NOTE
When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions
NOTE
When replacing or re-packing bearings, grease seal replacement is required. You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions

RUBBER JOINTS (METALASTIC)

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

ConditionCodeProcedure
Drive flange bentARequire repair or replacement
Drive flange damaged, affecting performanceARequire replacement
Rubber drive joint cracked2Suggest replacement
Rubber drive joint damaged, affecting performanceARequire replacement
Rubber drive joint split between mounting holesARequire replacement
Rubber drive joint torn at mounting holesARequire replacement
Rubber drive joint weather-crackedNo service suggested or required

SCREENS

ConditionCodeProcedure
At service interval3Suggest replacement
Bent, affecting performanceARequire repair or replacement
Exceeding service interval3Suggest replacement
MissingCRequire replacement
Near service interval3Suggest replacement
RestrictedARequire repair or replacement
NOTE: Further inspection may be required to determine the source of restriction or contamination.
TornARequire replacement
Worn, affecting performance (metal or nylon screen type)ARequire repair or replacement
NOTE
Further inspection may be required to determine the source of restriction or contamination.

SEALS (METAL CLAD)

ConditionCodeProcedure
LeakingARequire repair or replacement
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.
NOTE
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

ConditionCodeProcedure
LeakingARequire repair or replacement
NOTE: Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.
NOTE
Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.

SELECTOR INTERLOCK SYSTEMS

Note. See: Actuators (Electrical), Cables, Linkages (External), Switches

ConditionCodeProcedure
BindingARequire repair or replacement
BrokenARequire repair or replacement
Components missingCRequire replacement of missing components
Loose, affecting performanceARequire repair or replacement
Out of adjustmentBRequire repair
Worn, affecting performanceARequire repair or replacement

SENSORS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire repair or replacement
NOTE: Inoperative includes intermittent operation or out of specification.
Leaking (vacuum/fluid/air)ARequire replacement
Out of adjustmentBFurther inspection required
NOTE: Follow OEM recommended adjustment procedures. Repair or replace if out of specification.
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation or out of specification.
NOTE
Follow OEM recommended adjustment procedures. Repair or replace if out of specification.
NOTE
Determine cause and correct prior to repair or replacement of part.

SERVOS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
Leaking (vacuum)ARequire repair or replacement
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Suggest repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)

Note. See: Actuators (Electrical), Cables, Linkages (External), Switches

ConditionCodeProcedure
BindingARequire repair or replacement
BrokenARequire repair or replacement
Components missingCRequire replacement of missing components
Loose, affecting performanceARequire repair or replacement
Out of adjustmentBRequire repair
Worn, affecting performanceARequire repair or replacement

SIDE COVERS

ConditionCodeProcedure
Bent, interfering with filter or other internal componentsARequire repair or replacement
LeakingARequire repair or replacement

SLIP YOKES

ConditionCodeProcedure
Bearing cap bore distortedARequire repair or replacement
BentARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn close to the end of their useful life1Suggest replacement
Splines worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement

SOLENOIDS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware.
Attaching hardware not functioningARequire repair or replacement of hardware.
Connector (Weatherpack type) leakingARequire repair or replacement.
Connector brokenARequire repair or replacement.
Connector melted, affecting performanceARequire repair or replacement.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement.
InoperativeARequire replacement.
NOTE: Inoperative includes intermittent operation.
MissingCRequire replacement.
Noisy2Suggest repair or replacement.
Out of adjustmentBRequire repair or replacement.
Terminal brokenARequire repair or replacement.
Terminal burned, affecting performanceARequire repair or replacement.
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement.
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement.
Terminal corroded, not affecting performance1Suggest repair or replacement.
Terminal loose, affecting performanceBRequire repair or replacement.
Terminal loose, not affecting performance1Suggest repair or replacement.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

ConditionCodeProcedure
Air gap incorrectBRequire adjustment or replacement
NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause.
Attaching hardware missingCRequire replacement of hardware
Attaching hardware threads damagedARequire repair or replacement of hardware
Attaching hardware threads stripped (threads missing)ARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
ContaminatedARequire repair or replacement
NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement.
InoperativeARequire repair or replacement
NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
LeakingBRequire repair or replacement
LooseARequire repair or replacement
MissingCRequire replacement
Resistance out of specificationBRequire repair or replacement
Sensor housing cracked2Suggest replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Wire lead conductors exposedBRequire repair or replacement
Wire lead corrodedARequire repair or replacement
Wire lead misroutedBRequire re-routing according to vehicle manufacturer's specifications
Wire lead openARequire repair or replacement
Wire lead shortedARequire repair or replacement
NOTE
If a sensor is not adjustable, further inspection is required to identify and correct cause.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine source of contamination, such as metal particles or water. Require repair or replacement.
NOTE
Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
NOTE
Determine cause and correct prior to repair or replacement of part.

SPEEDOMETER- DRIVEN GEAR HOUSING

ConditionCodeProcedure
Application incorrectBRequire replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
LeakingBRequire repair or replacement
MissingCRequire replacement
Teeth brokenARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement
NOTE
Inoperative includes intermittent operation.

SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)

ConditionCodeProcedure
Application incorrectBRequire replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
LeakingBRequire repair or replacement
MissingCRequire replacement
Teeth brokenARequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn close to the end of its useful life1Suggest replacement
Worn, affecting performanceARequire replacement
NOTE
Inoperative includes intermittent operation.

SPEEDOMETER/ODOMETER HEADS (MECHANICAL)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Lens brokenARequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only.
Lens cloudy2Suggest repair or replacement
NOTE: If lens is available as a separate part, suggest replacement of lens only.
Lens missingCRequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only.
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.
Noisy2Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
If lens is available as a separate part, require replacement of lens only.
NOTE
If lens is available as a separate part, suggest replacement of lens only.
NOTE
If lens is available as a separate part, require replacement of lens only.
NOTE
Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.

SPEEDOMETERS/ODOMETERS (ELECTRONIC)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
LeakingBRequire replacement
Lens brokenARequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only.
Lens cloudy2Suggest repair or replacement
NOTE: If lens is available as a separate part, suggest replacement of lens only.
Lens missingCRequire repair or replacement
NOTE: If lens is available as a separate part, require replacement of lens only .
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.
Mechanical head noisy2Suggest repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
If lens is available as a separate part, require replacement of lens only.
NOTE
If lens is available as a separate part, suggest replacement of lens only.
NOTE
If lens is available as a separate part, require replacement of lens only .
NOTE
Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.
NOTE
Determine cause and correct prior to repair or replacement of part.

SWITCHES

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Binding, affecting performanceARequire repair or replacement
Binding, not affecting performance2Suggest repair or replacement
BrokenARequire repair or replacement
Burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Cracked, affecting performanceARequire repair or replacement
Cracked, not affecting performance1Suggest repair or replacement
LeakingBRequire repair or replacement
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, or failure to perform all functions.
Melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
MissingCRequire replacement
Out of adjustmentBRequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Won't returnARequire repair or replacement
Worn1Suggest replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Includes inoperative, intermittent operation, or failure to perform all functions.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

TONE WHEELS

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

ConditionCodeProcedure
Alignment incorrectBRequire repair or replacement
BentBRequire replacement
Contaminated, affecting performanceARequire repair. Identify and correct cause
CrackedARequire replacement
LooseARequire replacement of worn parts
MissingCRequire replacement
Number of teeth incorrectBRequire replacement
Teeth brokenARequire replacement
Teeth damaged, affecting performanceARequire replacement

TOOTHED RINGS (TONE WHEEL)

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

ConditionCodeProcedure
Alignment incorrectBRequire repair or replacement
BentBRequire replacement
Contaminated, affecting performanceARequire repair. Identify and correct cause
CrackedARequire replacement
LooseARequire replacement of worn parts
MissingCRequire replacement
Number of teeth incorrectBRequire replacement
Teeth brokenARequire replacement
Teeth damaged, affecting performanceARequire replacement

TORQUE CONVERTERS

ConditionCodeProcedure
Converter clutch lock-up operation is faultyARequire replacement
Cover shell damaged, affecting performanceARequire replacement
Does not meet stall speed specificationBRequire replacement
End play exceeds specificationsBRequire replacement
Hub brokenARequire replacement
Hub crackedARequire replacement
Internal component failureARequire replacement
LeakingBRequire repair or replacement
Pilot brokenARequire replacement
Pilot worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Weights missingCRequire replacement

TRANSAXLE MOUNTS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BrokenARequire replacement
Leaking (hydraulic mount)ARequire replacement
Mounting hole worn, affecting performanceARequire replacement
Mounting hole worn, not affecting performanceNo service suggested or required
Rubber deteriorated, affecting performanceARequire replacement
Rubber deteriorated, not affecting performanceNo service suggested or required
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

TRANSDUCERS (TRANSMISSION)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire repair or replacement
NOTE: Inoperative includes intermittent operation or out of specification.
Leaking (vacuum/fluid/air)ARequire replacement
Out of adjustmentBFurther inspection required
NOTE: Follow OEM recommended adjustment procedures. Repair or replace if out of specification.
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation or out of specification.
NOTE
Follow OEM recommended adjustment procedures. Repair or replace if out of specification.
NOTE
Determine cause and correct prior to repair or replacement of part.

TRANSFER CASE ASSEMBLIES

ConditionCodeProcedure
Any internal component failure that requires removal of the assembly from the vehicle for service.ARequire repair or replacement of the transfer case differential assembly
NOTE: For components not requiring removal of the assembly, refer to the component listing.
NOTE
For components not requiring removal of the assembly, refer to the component listing.

TRANSFER CASE FLUID

ConditionCodeProcedure
Additive depletionARequire replacement of fluid
Application incorrectBRequire replacement
NOTE: Determine and correct cause.
BurnedFurther inspection required
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the cause.
Contaminated, for example, fluid other than the specified fluid presentBRequire service
NOTE: If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
Contaminated, for example, fluid other than the specified fluid presentARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
Fluid at or beyond service interval3Suggest replacement
Fluid discoloredNo service suggested or required
NOTE: Further testing necessary to determine condition of fluid.
Fluid incorrectBRequire service
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrectBRequire correction of fluid level
OxidizedARequire replacement of fluid
Rubber master/ clutch cylinder cover gasket distorted or gummyARequire service
NOTE: If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.
Varnish deposits present on system components affecting performanceFurther inspection required
NOTE
Determine and correct cause.
NOTE
Fluid that is burned indicates a serious problem. Determine and correct the cause.
NOTE
If a fluid other than the specified fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill following OEM specified procedure with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct brake fluid.
NOTE
Further testing necessary to determine condition of fluid.
NOTE
If a fluid other than the correctly specified fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
NOTE
If an incorrect 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, 3) repair or replace all components having rubber parts, and 4) fill with correct fluid.

TRANSMISSION COOLERS

ConditionCodeProcedure
Air flow obstructionARequire repair
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connection leakingARequire repair or replacement
ContaminatedARequire repair or replacement
Corroded1Suggest repair or replacement
Fins damaged, affecting performanceARequire repair or replacement
Fins damaged, not affecting performanceNo service suggested or required
Internal restrictionsBRequire repair or replacement
LeakingBRequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire repair or replacement
Tubes damaged, affecting performanceARequire repair or replacement
Tubes damaged, not affecting performanceNo service suggested or required

TRANSMISSION MOUNTS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
BrokenARequire replacement
Leaking (hydraulic mount)ARequire replacement
Mounting hole worn, affecting performanceARequire replacement
Mounting hole worn, not affecting performanceNo service suggested or required
Rubber deteriorated, affecting performanceARequire replacement
Rubber deteriorated, not affecting performanceNo service suggested or required
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

TRANSMISSION PANS

ConditionCodeProcedure
Bent, interfering with filter or other Internal componentsARequire repair or replacement
LeakingARequire repair or replacement

TRANSMISSION RANGE INDICATORS (PRNDL)

ConditionCodeProcedure
BindingARequire repair or replacement
BrokenARequire repair or replacement
Components missingCRequire replacement of missing components
Loose, affecting performanceARequire repair or replacement
Out of adjustmentBRequire repair
Worn, affecting performanceARequire repair or replacement

TUBES

ConditionCodeProcedure
Application incorrectBRequire replacement
At or beyond service interval3Suggest replacement
Connected incorrectlyARequire repair
Corroded, not reusable1Suggest replacement
Cracked line or tubeARequire replacement
Hard hose1Suggest replacement
Inner fabric (webbing) damagedARequire replacement
Insufficient clamping force, allowing hose to leakARequire repair or replacement
LeakingARequire repair or replacement
Melted1Suggest repair or replacement
MissingCRequire replacement
Outer covering damaged1Suggest replacement
Outer covering damaged to the extent that the inner fabric is visibleARequire replacement
Protective sleeves damaged2Suggest replacement of sleeves
Protective sleeves missingCSuggest replacement of sleeves
Restricted, affecting performanceARequire repair or replacement
Restricted, not affecting performance2Suggest repair or replacement
Routed incorrectlyBSuggest replacement
Safety clip missingCRequire replacement
Spongy1Suggest repair or replacement
StrippedARequire replacement
Surface cracked (weather-checked)1Suggest repair or replacement
SwollenBRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Type incorrect2Suggest repair or replacement

UNIVERSAL JOINTS (CARDAN OR CROSS TYPE)

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Bearing cap distortedBRequire replacement
BindingARequire replacement
Cross (trunion) worn, affecting performanceARequire replacement
Double cardan centering ball damagedARequire replacement
Double cardan centering ball worn, affecting performanceARequire replacement
Double cardan centering spring brokenARequire replacement
Double cardan centering spring missingCRequire replacement
Double cardan centering spring weakARequire replacement
End cap seal cracked2Suggest replacement
End cap seal missingCRequire replacement of seal
Grease fitting brokenARequire replacement of grease fitting
NOTE: A broken grease fitting does not require replacement of the U-Joint.
Grease fitting missingCRequire replacement of grease fitting
NOTE: A missing grease fitting does not require replacement of the U-Joint.
Rust-colored powder around end cap sealsARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Worn, affecting performanceARequire replacement
NOTE
A broken grease fitting does not require replacement of the U-Joint.
NOTE
A missing grease fitting does not require replacement of the U-Joint.

VACUUM CONTROLS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
Leaking (vacuum)ARequire repair or replacement
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Require repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

VACUUM HOSES

ConditionCodeProcedure
Application incorrectBRequire replacement
At or beyond service interval3Suggest replacement
Connected incorrectlyARequire repair
Corroded, not reusable1Suggest replacement
Cracked line or tubeARequire replacement
Hard hose1Suggest replacement
Inner fabric (webbing) damagedARequire replacement
Insufficient clamping force, allowing hose to leakARequire repair or replacement
LeakingARequire repair or replacement
Melted, affecting performanceBRequire repair or replacement
MissingCRequire replacement
Outer covering damaged1Suggest replacement
Outer covering damaged to the extent that the inner fabric is visibleARequire replacement
Protective sleeves damaged2Suggest replacement of sleeves
Protective sleeves missingCSuggest replacement of sleeves
Restricted, affecting performanceARequire repair or replacement
Restricted, not affecting performance2Suggest repair or replacement
Routed incorrectlyBSuggest replacement
Safety clip missingCRequire replacement
Spongy1Suggest repair or replacement
StrippedARequire replacement
Surface cracked (weather-checked)1Suggest repair or replacement
SwollenBRequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Type incorrect2Suggest repair or replacement

VACUUM MOTORS

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
InoperativeARequire replacement
NOTE: Inoperative includes intermittent operation.
Leaking (vacuum)ARequire repair or replacement
Linkage bent, affecting performanceARequire repair or replacement of linkage
Linkage bent, not affecting performance2Suggest repair or replacement of linkage
Linkage binding, affecting performanceARequire repair or replacement of linkage
Linkage binding, not affecting performance1Suggest repair or replacement of linkage
Linkage brokenARequire repair or replacement of linkage
Linkage loose, affecting performanceARequire repair or replacement of linkage
Linkage loose, not affecting performance1Suggest repair or replacement of linkage
Linkage missingCRequire replacement
Linkage noisy2Suggest repair or replacement
MissingCRequire replacement
Noisy2Suggest repair or replacement
Out of adjustmentBRequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Inoperative includes intermittent operation.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

VACUUM-OPERATED SWITCHES

ConditionCodeProcedure
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Binding, affecting performanceARequire repair or replacement
Binding, not affecting performance2Suggest repair or replacement
BrokenARequire repair or replacement
Burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Cracked, affecting performanceARequire repair or replacement
Cracked, not affecting performance1Suggest repair or replacement
LeakingBRequire repair or replacement
MalfunctioningARequire repair or replacement
NOTE: Includes inoperative, intermittent operation, or failure to perform all functions.
Melted, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Melted, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
MissingCRequire replacement
Out of adjustmentBRequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Won't returnARequire repair or replacement
Worn affecting performanceBRequire replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Includes inoperative, intermittent operation, or failure to perform all functions.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

VEHICLE SPEED SENSORS

ConditionCodeProcedure
Air gap incorrectBRequire adjustment or replacement
NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause.
Attaching hardware missingCRequire replacement of hardware
Attaching hardware threads damagedARequire repair or replacement of hardware
Attaching hardware threads stripped (threads missing)ARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
ContaminatedARequire repair or replacement
NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement.
InoperativeBRequire repair or replacement
NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
LeakingARequire repair or replacement
LooseARequire repair or replacement
MissingCRequire replacement
Resistance out of specificationBRequire repair or replacement
Sensor housing cracked2Suggest replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal corroded, affecting performanceARequire repair or replacement
Terminal corroded, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Wire lead conductors exposedBRequire repair or replacement
Wire lead corrodedARequire repair or replacement
Wire lead misroutedBRequire re-routing according to vehicle manufacturer's specifications
Wire lead openARequire repair or replacement
Wire lead shortedARequire repair or replacement
NOTE
If a sensor is not adjustable, further inspection is required to identify and correct cause.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine source of contamination, such as metal particles or water. Require repair or replacement.
NOTE
Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
NOTE
Determine cause and correct prior to repair or replacement of part.

VENTS

ConditionCodeProcedure
BrokenARequire replacement
MissingCRequire replacement
PluggedARequire repair or replacement
NOTE: A plugged vent may force fluid past the seal.
NOTE
A plugged vent may force fluid past the seal.

VIBRATION DAMPERS

ConditionCodeProcedure
BrokenARequire replacement
MissingCRequire replacement
Out of positionBRequire repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement

WHEEL ATTACHMENT HARDWARE

Note. For conditions noted below, also check conditions of wheel stud holes. Proper lug nut torque is essential. Follow recommended torque specifications and tightening sequence. DO NOT lubricate threads unless specified by the vehicle manufacturer.

ConditionCodeProcedure
BentARequire replacement
BrokenARequire replacement
NOTE: Some manufacturers require replacement of all studs on that wheel if two or more studs or nuts on the same wheel are broken or missing.
LooseARequire repair or replacement of affected component
Lug nut installed backwardBRequire repair or replacement
Lug nut mating surface dishedARequire replacement of nut
Lug nut mating type incorrectBRequire replacement of nut
Lug nut roundedARequire replacement of nut
NOTE: Only required if removing wheel.
Lug nut seizedARequire replacement of nut
NOTE: Only required if removing wheel.
Stud incorrectBRequire replacement of stud
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
NOTE
Some manufacturers require replacement of all studs on that wheel if two or more studs or nuts on the same wheel are broken or missing.
NOTE
Only required if removing wheel.
NOTE
Only required if removing wheel.

WHEEL SPEED SENSORS

ConditionCodeProcedure
Air gap incorrectBRequire adjustment or replacement
NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause.
Attaching hardware missingCRequire replacement of hardware
Attaching hardware threads damagedARequire repair or replacement of hardware
Attaching hardware threads stripped (threads missing)ARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector missingCRequire replacement
ContaminatedARequire repair or replacement
NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement.
InoperativeARequire repair or replacement
NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
LeakingBRequire repair or replacement
LooseARequire repair or replacement
MissingCRequire replacement
Resistance out of specificationBRequire repair or replacement
Sensor housing cracked2Suggest replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
Wire lead conductors exposedBRequire repair or replacement
Wire lead corrodedARequire repair or replacement
Wire lead misroutedBRequire re-routing according to vehicle manufacturer's specifications
Wire lead openARequire repair or replacement
Wire lead shortedARequire repair or replacement
NOTE
If a sensor is not adjustable, further inspection is required to identify and correct cause.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine source of contamination, such as metal particles or water. Require repair or replacement.
NOTE
Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure.
NOTE
Determine cause and correct prior to repair or replacement of part.

WIRING HARNESSES AND CONNECTORS

ConditionCodeProcedure
Application incorrectBRequire repair or replacement
Attaching hardware brokenARequire repair or replacement of hardware
Attaching hardware missingCRequire replacement of hardware
Attaching hardware not functioningARequire repair or replacement of hardware
Connector (Weatherpack type) leakingARequire repair or replacement
Connector brokenARequire repair or replacement
Connector meltedARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Insulation damaged, conductors exposedARequire repair or replacement
Insulation damaged, conductors not exposed1Suggest replacement
OpenARequire repair or replacement
Protective shield (conduit) melted2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Protective shield (conduit) missingCSuggest repair or replacement
Resistance (voltage drop) out of specificationARequire repair or replacement
Routed incorrectlyBRequire repair
Secured incorrectlyBRequire repair
ShortedARequire repair or replacement
Terminal brokenARequire repair or replacement
Terminal burned, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal burned, not affecting performance2Suggest repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, affecting performanceARequire repair or replacement
NOTE: Determine cause and correct prior to repair or replacement of part.
Terminal corroded, not affecting performance1Suggest repair or replacement
Terminal loose, affecting performanceBRequire repair or replacement
Terminal loose, not affecting performance1Suggest repair or replacement
Transmission connector leakingSee Transmission Assembly
Voltage drop out of specificationARequire repair or replacement
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.
NOTE
Determine cause and correct prior to repair or replacement of part.

YOKES AND SLIP YOKES

ConditionCodeProcedure
Bearing cap bore distortedARequire repair or replacement
BentARequire replacement
Bolt holes elongatedARequire repair or replacement
Bushing or seal surface worn, affecting performanceARequire repair or replacement
Leaking through soft yoke plugARequire repair or replacement of soft yoke plug
Retainer strap bentARequire replacement of retainer strap
Slip yoke brokenARequire replacement
Splines worn close to the end of their useful life1Suggest replacement
Splines worn, affecting performanceARequire replacement
Threads damagedARequire repair or replacement
Threads stripped (threads missing)ARequire replacement
U-bolt damaged, affecting performanceARequire replacement of U-bolts
Yoke damaged, affecting performanceARequire repair or replacement

REASON CODE EXPLANATION

CodeReason
Required
APart No Longer Performs Intended Purpose
BPart Does Not Meet A Design Specification ( Regardless Of Performance)
CPart Is Missing
Suggested/Optional
1Part Is Close To The End Of Its Useful Life
2To Address A Customer Need, Convenience Or Request
3To Comply With Maintenance Recommended By The Vehicle's Original Equipment Manufacturer
4Technician's Recommendation Based On Substantial And Informed Experience
5To Comply With Maintenance Recommended By AMRA/MAP

AUTOMOTIVE TERMINOLOGY & DEFINITIONS