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.
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.
No work will be performed without the customer's prior approval.
A minimum limited warranty will be offered of 90 days or 4,000 miles, whichever comes first, covering parts and labor.
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.
- Example: An exhaust pipe has corroded severely and has a hole in it through which exhaust gases are leaking. Replacement of the exhaust pipe in this case is required due to functional failure.
- Example: A brake rotor has been worn to the point where it measures less than the vehicle manufacturer's discard specifications. Replacement of the rotor is required because it does not meet design specifications.
Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customer's need, convenience or request. If a customer's vehicle has one of these conditions, the procedure may be only to suggest service.
- Example: An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customer's convenience in avoiding a future problem.
- Example: The customer desires improved ride and/or handling, but the vehicle's shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customer's wishes. In this case, replacement of the shocks or struts may not be sold as a requirement.
A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.
The following reasons may be used for required and suggested services. These codes are shown in the "Code" column of the MAP Uniform Inspection & Communications Standards that follow
| Reasons to Require Repair or Replacement | Reasons to Suggest Repair or Replacement |
| Part no longer performs intended purpose Part does not meet a design specification (regardless of performance) Part is missing | Part 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)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Require repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest 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)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware. |
| Attaching hardware missing | C | Require replacement of hardware. |
| Attaching hardware not functioning | A | Require repair or replacement of hardware. |
| Connector (Weatherpack type) leaking | A | Require repair or replacement. |
| Connector broken | A | Require repair or replacement. |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking (vacuum) | A | Require repair or replacement |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| 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
| Condition | Code | Procedure |
| Any internal component failure that requires removal of the assembly from the vehicle for service. | A | Require 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
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | B | Require 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 present | A | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Varnish deposits present on system components affecting performance | | Further 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
| Condition | Code | Procedure |
| Bent, affecting performance | A | Require replacement |
| Bent, beyond specification | B | Require repair or replacement |
| Broken | A | Require replacement |
| End play exceeds specifications | B | Require repair or replacement |
| Flange bent | A | Require replacement |
| Flange threads stripped | A | Require repair or replacement |
| Twisted | A | Require replacement |
| Worn, affecting performance | A | Require 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.
| Condition | Code | Procedure |
| Bearing end-play exceeds specifications | B | Require 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 assembly | B | Require replacement of bearing assembly |
| NOTE |
| If proper adjustment can't be obtained, require replacement of bearing assembly. |
BELL CRANKS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bent, affecting performance | A | Require repair or replacement |
| Broken | A | Require repair or replacement |
| Cracked | A | Require repair or replacement |
| Missing | C | Require replacement |
| Worn, affecting performance | A | Require repair or replacement |
BELL HOUSINGS
| Condition | Code | Procedure |
| Bearing race loose in bore | A | Require repair or replacement |
| Broken, affecting performance | A | Require repair or replacement |
| Cracked | A | Require repair or replacement |
| Dowel pin holes worn, affecting performance | | See Dowel Pins, Guides, and Pilot Holes |
| Leaking Coolant | B | Require Repair or Replacement |
| NOTE: This condition is found mostly on Hybrid vehicles with a liquid cooled inverter. |
| Machined surfaces damaged, affecting performance | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require repair or replacement |
| NOTE |
| This condition is found mostly on Hybrid vehicles with a liquid cooled inverter. |
BUSHINGS (EXTERNAL)
| Condition | Code | Procedure |
| Attaching hardware bent | B | Require repair or replacement of bent part if available, otherwise, replace bushing |
| Attaching hardware broken | A | Require repair or replacement of broken part if available, otherwise, replace bushing |
| Attaching hardware corroded, affecting structural Integrity | A | Require repair or replacement of corroded part if available, otherwise, replace bushing |
| Attaching hardware incorrect | B | Require repair or replacement of incorrect part if available, otherwise, replace bushing |
| Attaching hardware loose | A | Require repair or replacement of loose part if available, otherwise, replace bushing |
| Attaching hardware missing | C | Require repair or replacement of missing part if available, otherwise, replace bushing |
| Attaching hardware threads damaged | A | Require repair or replacement of part with damaged threads if available, otherwise, replace bushing |
| Attaching hardware threads stripped (threads missing) | A | Require repair or replacement of part with damaged threads if available, otherwise, replace bushing |
| Binding | A | Require repair or replacement |
| Contaminated | 1 | Suggest replacement |
| Deteriorated, affecting performance | A | Require repair or replacement |
| Distorted, affecting performance | A | Require repair or replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Further 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 bushing | A | Require replacement |
| Seized | A | Require replacement |
| Shifted out of position | B | Require repair or replacement |
| Split | A | Require replacement |
| Surface cracking (weather-checked) | | No service suggested or required |
| Worn affecting performance | A | Require repair or replacement |
| Worn, close to the end of Its useful life | 1 | Suggest 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)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bent | A | Require repair or replacement |
| Binding | A | Require repair or replacement |
| Bracket bent, affecting performance | A | Require repair or replacement |
| Bracket bent, not affecting performance | 2 | Suggest repair or replacement of bracket |
| Bracket broken, affecting performance | A | Require replacement |
| Bracket broken, not affecting performance | 2 | Suggest repair or replacement of bracket |
| Bracket corroded, affecting performance | A | Require repair or replacement |
| Bracket cracked, affecting performance | A | Require repair or replacement |
| Bracket cracked, not affecting performance | 1 | Suggest repair or replacement |
| Bracket loose, affecting performance | A | Require repair or replacement |
| Bracket loose, not affecting performance | 1 | Suggest repair or replacement |
| Bracket missing | C | Require replacement |
| Broken | A | Require replacement |
| Cracked | B | Require repair or replacement |
| Disconnected | A | Require repair or replacement |
| Kinked | A | Require repair or replacement |
| Melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Routed incorrectly, affecting performance | B | Require repair |
| Seized | A | Require repair or replacement |
| NOTE |
| Determine cause and correct prior to repair or replacement of part. |
CABLES (TV, DETENT AND SHIFT)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bent | A | Require repair or replacement |
| Binding | A | Require repair or replacement |
CARRIER BEARINGS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when rotated as an assembly | A | Require replacement of bearing assembly |
| Bracket bent, affecting performance | A | Require repair or replacement |
| Bracket bent, not affecting performance | | No service suggested or required |
| Bracket broken, affecting performance | A | Require replacement |
| Bracket broken, not affecting performance | 2 | Suggest repair or replacement of bracket |
| Bracket corroded, affecting performance | A | Require repair or replacement |
| Bracket corroded, not affecting performance | 2 | Suggest repair or replacement |
| Bracket cracked, affecting performance | A | Require repair or replacement |
| Bracket cracked, not affecting performance | 1 | Suggest repair or replacement |
| Bracket holes elongated, affecting performance | A | Require repair or replacement |
| Bracket holes elongated, not affecting performance | | No service suggested or required |
| Bracket loose, affecting performance | A | Require repair or replacement |
| Bracket loose, not affecting performance | 1 | Suggest repair or replacement |
| Bracket missing | C | Require replacement |
| Cracked | B | Require replacement |
| Rough (brinelling, spalling) | A | Require replacement |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Seized | A | Require replacement |
CLUTCH CABLES AND CABLE HOUSINGS
| Condition | Code | Procedure |
| Broken | A | Require replacement |
| Cable bent | A | Require replacement |
| Cable binding | A | Require repair or replacement |
| Cable mounting loose | B | Require repair or replacement |
| Cable out of adjustment | B | Require repair or replacement |
| Frayed | B | Require replacement |
| Housing heat -damaged | 1 | Suggest replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Seized | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require replacement |
CLUTCH DISCS (MANUAL TRANSMISSIONS)
| Condition | Code | Procedure |
| Backing plate cracked | B | Require replacement |
| Broken | A | Require replacement |
| Contaminated with oil | A | Require replacement |
| NOTE: Determine source of oil and correct prior to repair or replacement of clutch disc. |
| Damper cushion broken | A | Require replacement |
| Damper cushion collapsed | A | Require replacement |
| Damper spring collapsed | A | Require replacement |
| Damper spring missing | C | Require replacement |
| NOTE: Not all clutch discs have springs in all spring chambers on the disc. |
| Friction material cracked through | B | Require replacement |
| Friction material flaking or chunking | B | Require replacement |
| Friction material surface cracking | | No service suggested or required |
| Grooved | B | No service suggested or required unless the pressure plate or flywheel is being resurfaced or replaced. In this case, replacement of clutch disc is required |
| Ridged | B | No service suggested or required unless the pressure plate or flywheel is being resurfaced or replaced. In this case, replacement of clutch disc is required |
| Splines worn, affecting performance | A | Require replacement |
| Warped, affecting performance. | A | Require replacement |
| Wear exceeds specifications (where applicable) | B | Require replacement |
| Worn, affecting performance | A | Require replacement |
| Worn, not affecting performance yet close to the end of its useful life | 1 | Suggest 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
| Condition | Code | Procedure |
| Bent, affecting performance | B | Require replacement |
| Broken | A | Require repair or replacement |
| Cracked | B | Require repair or replacement |
| Worn, affecting performance | A | Require replacement |
| Worn, not affecting performance yet close to the end of its useful life | 1 | Suggest replacement |
CLUTCH LINKAGES (MECHANICAL)
| Condition | Code | Procedure |
| Components missing | C | Require replacement of missing components |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Worn to the extent that it no longer performs its intended function | A | Require repair or replacement |
CLUTCH MASTER CYLINDERS
| Condition | Code | Procedure |
| Cover gasket distorted | A | Require replacement of cover gasket |
| Cover gasket gummy | A | Require replacement of cover gasket |
| NOTE: This condition may indicate contaminated fluid. Further inspection required. |
| Cylinder leaking fluid from rear of bore | A | Require repair or replacement |
| Cylinder leaking fluid internally | A | Require replacement |
| Dust boot missing | C | Require replacement of dust boot |
| Dust boot punctured | A | Require replacement of dust boot |
| Dust boot torn | A | Require replacement of dust boot |
| Fluid level incorrect | B | Require fluid level adjustment |
| Housing damaged, affecting performance | A | Require repair or replacement |
| Master cylinder has residue in reservoir | 2 | Further inspection required |
| NOTE: Do not replace master cylinder unless it exhibits conditions listed for replacement. |
| Pushrod out of adjustment | B | Require Repair or Replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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
| Condition | Code | Procedure |
| Bent, affecting performance | A | Require repair or replacement |
| Bent, not affecting performance | 2 | Suggest repair or replacement |
| Broken | A | Require repair or replacement |
| Pedal pad missing | C | Require replacement of pedal pad |
| Pivot bushings worn, affecting performance | A | Require replacement of pivot bushings |
CLUTCH PIVOTS
| Condition | Code | Procedure |
| Bent, affecting performance | A | Require replacement |
| Broken | A | Require repair or replacement |
| Cracked | B | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require replacement |
| Worn, not affecting performance, but close to the end of its useful life | 2 | Suggest replacement |
CLUTCH PRESSURE PLATES
| Condition | Code | Procedure |
| Balance weight missing | C | Require replacement |
| Broken | A | Require replacement |
| Contact surface distorted | B | Require replacement |
| Cracks | B | Require replacement |
| Fingers bent | A | Require replacement |
| Hard spots | B | Require replacement |
| Scored | B | Require replacement |
| Spring rate less than specifications | B | Require replacement |
| Worn beyond specifications | B | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
CLUTCH RELEASE BEARINGS
| Condition | Code | Procedure |
| Collar broken | A | Require replacement |
| Cracked | B | Require replacement |
| Rough when rotated as an assembly | B | Require replacement |
| Seized | A | Require replacement |
| Wear exceeds specifications | B | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
| Condition | Code | Procedure |
| Bearing rough when rotated as an assembly | B | Require replacement |
| Bearing seized | A | Require replacement |
| Bleeder pipe leaks | A | Require repair or replacement |
| Carrier assembly worn, affecting performance | A | Require replacement |
| Collar broken | A | Require replacement |
| Cracked | B | Require replacement |
| Housing leaks | A | Require replacement |
| Inoperative | A | Require replacement |
| Release binding | A | Require replacement |
| Spring broken | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require replacement |
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)
| Condition | Code | Procedure |
| Binding | A | Require repair or replacement |
| Bleeder port damaged (not repairable) | A | Require replacement |
| NOTE: Only required if the hydraulic system must be opened. |
| Bleeder port damaged (repairable) | A | Require repair |
| NOTE: Only required if the hydraulic system must be opened. |
| Bleeder screw broken off in slave cylinder | A | Require replacement |
| NOTE: Only required if the hydraulic system must be opened. |
| Bleeder screw seized | A | Require 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) | B | Require replacement |
| Bore grooved | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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
| Condition | Code | Procedure |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent, affecting performance | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn close to the end of their useful life | 1 | Suggest replacement |
| Splines worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement |
CONNECTORS
| Condition | Code | Procedure |
| Application incorrect | B | Require repair or replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Insulation damaged, conductors exposed | A | Require repair or replacement |
| Insulation damaged, conductors not exposed | 1 | Suggest replacement |
| Open | A | Require repair or replacement |
| Protective shield (conduit) melted | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Protective shield (conduit) missing | C | Suggest repair or replacement |
| Resistance (voltage drop) out of specification | A | Require repair or replacement |
| Routed incorrectly | B | Require repair |
| Secured incorrectly | B | Require repair |
| Shorted | A | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Transmission connector leaking | See Transmission Assembly | |
| Voltage drop out of specification | A | Require repair or replacement |
| 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
| Condition | Code | Procedure |
| Inoperative | A | Require replacement |
| Installed incorrectly | A | Require repair |
| Leaking | A | Require repair or replacement |
| Restricted | A | Require repair or replacement |
COOLER LINES
| Condition | Code | Procedure |
| Abrasion damage, affecting structural integrity | A | Require repair or replacement |
| Abrasion damage, not affecting structural integrity | | No service suggested or required |
| Application incorrect | B | Require replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Clamp corroded, not reusable | 1 | Suggest replacement |
| NOTE: If clamp removed, require replacement. |
| Connected incorrectly | A | Require repair |
| Corroded, affecting structural integrity | A | Require replacement |
| Corroded, not affecting structural integrity | | No service suggested or required |
| Cracked | B | Require repair or replacement |
| Fitting type incorrect (such as compression fitting) | B | Require replacement |
| Flange leaking | A | Require repair or replacement |
| Insufficient clamping force, allowing hose to leak | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Melted | 1 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Outer covering damaged to the extent that the inner fabric is visible | A | Require replacement |
| Protective sleeves damaged | 2 | Suggest replacement of sleeves |
| Protective sleeves missing | C | Require replacement of sleeves |
| Restricted, affecting performance | A | Require repair or replacement |
| Routed incorrectly | B | Require repair |
| Swollen | 1 | Suggest replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Type incorrect | 2 | Suggest repair or replacement |
| NOTE |
| If clamp removed, require replacement. |
COOLERS
| Condition | Code | Procedure |
| Air flow obstruction | A | Require repair |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connection leaking | A | Require repair or replacement |
| Contaminated | A | Require repair or replacement |
| Corroded | 1 | Suggest repair or replacement |
| Fins damaged, affecting performance | A | Require repair or replacement |
| Fins damaged, not affecting performance | | No service suggested or required |
| Internal restrictions | B | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require repair or replacement |
| Tubes damaged, affecting performance | A | Require repair or replacement |
| Tubes damaged, not affecting performance | | No service suggested or required |
CV JOINTS
| Condition | Code | Procedure |
| Bearing, bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Boot clamp broken | A | Require repair or replacement of clamp |
| Boot clamp loose | A | Require repair or replacement of clamp |
| Boot clamp missing | C | Require repair or replacement of clamp |
| Boot leaking | A | Require replacement of CV boot |
| NOTE: Further inspection of joint required before replacing boot. |
| Boot surface cracked, not leaking | 2 | Suggest replacement of CV boot |
| Cage broken | A | Require repair or replacement of CV joint |
| Housing damaged to the extent that it no longer performs its intended function | A | Require 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 function | A | Require repair or replacement |
| NOTE: Housing assembly may appear blue in color from normal manufacturing process of heat treating the housing. |
| Internal parts binding | A | Require repair or replacement |
| Internal parts worn | A | Require repair or replacement |
| Lubricant missing | C | Require cleaning, inspection, and repacking of CV joint |
| Mounting holes elongated | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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.
| Condition | Code | Procedure |
| Any internal component failure that requires removal of the assembly from the vehicle for service. | A | Require 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
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | A | Require 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 present | B | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Rubber master/ clutch cylinder cover gasket distorted or gummy | A | Require 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 performance | | Further 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
| Condition | Code | Procedure |
| Broken | A | Require repair or replacement |
| Check ball missing | C | Require repair or replacement |
| Cracked | B | Require repair or replacement |
| Hold down bracket broken | A | Require repair or replacement |
| Hold down bracket missing | C | Require replacement |
| Leaking | B | Require repair or replacement |
| Missing | C | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
DIP STICKS (FLUID LEVEL INDICATORS)
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Broken | A | Require replacement |
| Compressed | A | Require repair or replacement |
| Missing | C | Require replacement |
| Modified | A | Require replacement |
| Stretched | A | Require repair or replacement |
DOWEL PINS, GUIDES AND PILOT HOLES
| Condition | Code | Procedure |
| Application incorrect | B | Require repair or replacement |
| Cracked | A | Require repair or replacement |
| Distorted | A | Require repair or replacement |
| Missing | C | Require replacement |
| Positioned incorrectly | B | Require repair or replacement |
| Stepped | A | Require repair or replacement |
| Worn to the extent that it no longer performs its intended function | A | Require repair or replacement |
DRAIN PLUGS AND GASKETS
| Condition | Code | Procedure |
| Leaking | A | Require repair or replacement |
| NOTE: Require inspection of mating and sealing surface and repair or replace as necessary. |
| Missing | C | Require replacement |
| Threads Damaged | A | Require repair or replacement |
| NOTE |
| Require inspection of mating and sealing surface and repair or replace as necessary. |
DRIVE SHAFT FLANGES
| Condition | Code | Procedure |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent, affecting performance | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn close to the end of their useful life | 1 | Suggest replacement |
| Splines worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement |
DRIVE SHAFTS AND HALF SHAFTS
| Condition | Code | Procedure |
| Balance weight missing | C | Require repair or replacement |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke |
| Out of balance | A | Require repair or replacement |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn, affecting performance | A | Require repair or replacement |
| Splines worn, not affecting performance, but close to the end of their useful life | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement of Yoke |
DUST BOOTS
| Condition | Code | Procedure |
| Cracked, not leaking | 1 | Suggest replacement |
| Leaking | A | Require repair or replacement |
| Missing | C | Require replacement |
| Torn | A | Require replacement |
| Weather checked, surface cracked | | No service suggested or required |
ENGINE MOUNTS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Broken | A | Require replacement |
| Leaking (hydraulic mount) | A | Require replacement |
| Mounting hole worn, affecting performance | A | Require replacement |
| Mounting hole worn, not affecting performance | | No service suggested or required |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Rubber deteriorated, not affecting performance | | No service suggested or required |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
EXCITER RINGS
| Condition | Code | Procedure |
| Alignment incorrect | B | Require repair or replacement |
| Bent | B | Require replacement |
| Contaminated, affecting performance | A | Require repair. Identify and correct cause |
| Cracked | B | Require replacement |
| Loose | A | Require replacement of worn parts |
| Missing | C | Require replacement |
| Number of teeth incorrect | B | Require replacement |
| Teeth broken | A | Require replacement |
| Teeth damaged, affecting performance | A | Require replacement |
FILLER TUBES
| Condition | Code | Procedure |
| Broken | A | Require repair or replacement |
| Check ball missing | C | Require repair or replacement |
| Cracked | B | Require repair or replacement |
| Hold down bracket broken | A | Require repair or replacement |
| Hold down bracket missing | C | Require replacement |
| Leaking | A | Require repair or replacement |
| Missing | C | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
FILTERS AND SCREENS
| Condition | Code | Procedure |
| At service interval | 3 | Suggest replacement |
| Bent, affecting performance | A | Require repair or replacement |
| Exceeding service interval | 3 | Suggest replacement |
| Missing | C | Require replacement |
| Near service interval | 3 | Suggest replacement |
| Restricted | A | Require repair or replacement |
| NOTE: Further inspection may be required to determine the source of restriction or contamination. |
| Torn | A | Require replacement |
| Worn, affecting performance (metal or nylon screen type) | A | Require repair or replacement |
| NOTE |
| Further inspection may be required to determine the source of restriction or contamination. |
FLANGES
| Condition | Code | Procedure |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent, affecting performance | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn close to the end of their useful life | 1 | Suggest replacement |
| Splines worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement |
FLEX PLATES
| Condition | Code | Procedure |
| Bent, affecting performance | A | Require replacement |
| Bent, not affecting performance | | No service suggested or required |
| Bolt or stud holes elongated | B | Require replacement |
| Broken | A | Require replacement |
| Cracked | B | Require replacement |
| Ring gear worn close to the end of its useful life | 1 | Suggest replacement |
| Ring gear worn to the extent that it no longer performs its intended function | A | Require replacement |
| Weights missing | A | Require repair or replacement |
FLUID LEVEL INDICATORS
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Broken | A | Require replacement |
| Compressed | A | Require repair or replacement |
| Missing | C | Require replacement |
| Modified | A | Require replacement |
| Stretched | A | Require repair or replacement |
FLUIDS AND LUBRICANTS
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | B | Require 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 present | A | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Rubber master/ clutch cylinder cover gasket distorted or gummy | A | Require 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 performance | | Further 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.
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Cracked (other than mounting area) | A | Require repair or replacement of hardware |
| NOTE: Some manufacturers allow slight surface cracking in the friction surface. |
| Cracks in mounting area | B | Require replacement |
| Hard spots | B | Require repair or replacement |
| Ring gear teeth worn, affecting performance | A | Require replacement of ring gear |
| Runout exceeds specifications | B | Require repair or replacement |
| Scored | B | Require repair or replacement |
| Surface cracks after resurfacing to manufacturer's minimum specifications | B | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Wear exceeds specifications | B | Require replacement |
| Worn, affecting performance | A | Require repair or replacement |
| Worn, not affecting performance, but close to the end of its useful life | 1 | Suggest repair or replacement |
| NOTE |
| Some manufacturers allow slight surface cracking in the friction surface. |
FORCE MOTORS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 1 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest 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
| Condition | Code | Procedure |
| Leaking | A | Require 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
| Condition | Code | Procedure |
| Application incorrect | B | Require repair or replacement |
| Cracked | A | Require repair or replacement |
| Distorted | A | Require repair or replacement |
| Missing | C | Require replacement |
| Positioned incorrectly | B | Require repair or replacement |
| Stepped | A | Require repair or replacement |
| Worn to the extent that it no longer performs its intended function | A | Require repair or replacement |
HALF SHAFTS
| Condition | Code | Procedure |
| Balance weight missing | C | Require repair or replacement |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Out of balance | A | Require repair or replacement |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn, affecting performance | A | Require repair or replacement |
| Splines worn, not affecting performance, but close to the end of their useful life | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement of yoke |
HOSES, LINES, AND TUBES
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| At or beyond service interval | 3 | Suggest replacement |
| Connected incorrectly | A | Require repair |
| Corroded, not reusable | 1 | Suggest replacement |
| Cracked line or tube | A | Require replacement |
| Hard hose | 1 | Suggest replacement |
| Inner fabric (webbing) damaged | A | Require replacement |
| Insufficient clamping force, allowing hose to leak | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Melted | 1 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Outer covering damaged | 1 | Suggest replacement |
| Outer covering damaged to the extent that the inner fabric is visible | A | Require replacement |
| Protective sleeves damaged | 2 | Suggest replacement of sleeves |
| Protective sleeves missing | 2 | Suggest replacement of sleeves |
| Restricted, affecting performance | A | Require repair or replacement |
| Restricted, not affecting performance | 2 | Suggest repair or replacement |
| Routed incorrectly | 2 | Suggest replacement |
| Safety clip missing | C | Require replacement |
| Spongy | 1 | Suggest repair or replacement |
| Stripped | A | Require replacement |
| Surface cracked (weather-checked) | 1 | Suggest repair or replacement |
| Swollen | B | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Type incorrect | 1 | Suggest repair or replacement |
HOUSINGS (BELL, CASE, TAIL(EXTENSION) AND AUXILIARY)
| Condition | Code | Procedure |
| Bearing race loose in bore | A | Require repair or replacement |
| Broken, affecting performance | A | Require repair or replacement |
| Cracked | B | Require repair or replacement |
| Dowel pin holes worn, affecting performance | A | Require repair or replacement |
| Machined surfaces damaged, affecting performance | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require repair or replacement |
HYDRAULIC FLUID
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | B | Require 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 present | A | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Rubber master/ clutch cylinder cover gasket distorted or gummy | A | Require 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 performance | | Further 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
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when rotated as an assembly | A | Require replacement of bearing assembly |
| Bracket bent, affecting performance | A | Require repair or replacement |
| Bracket bent, not affecting performance | | No service suggested or required |
| Bracket broken, affecting performance | A | Require replacement |
| Bracket broken, not affecting performance | 2 | Suggest repair or replacement of bracket |
| Bracket corroded, affecting performance | A | Require repair or replacement |
| Bracket corroded, not affecting performance | 2 | Suggest repair or replacement |
| Bracket cracked, affecting performance | A | Require repair or replacement |
| Bracket cracked, not affecting performance | 1 | Suggest repair or replacement |
| Bracket holes elongated, affecting performance | A | Require repair or replacement |
| Bracket holes elongated, not affecting performance | | No service suggested or required |
| Bracket loose, affecting performance | A | Require repair or replacement |
| Bracket loose, not affecting performance | 1 | Suggest repair or replacement |
| Bracket missing | C | Require replacement |
| Cracked | B | Require replacement |
| Rough (brinelling, spalling) | A | Require replacement |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Seized | A | Require replacement |
KEY INTERLOCK SYSTEMS
Note. See: Actuators (Electrical), Cables, Linkages (External), Switches
LIMITED SLIPS
| Condition | Code | Procedure |
| Any internal component failure that requires removal of the assembly from the vehicle for service. | A | Require 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
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| At or beyond service interval | 3 | Suggest replacement |
| Connected incorrectly | A | Require repair |
| Corroded, not reusable | 1 | Suggest replacement |
| Cracked line or tube | A | Require replacement |
| Hard hose | 1 | Suggest replacement |
| Inner fabric (webbing) damaged | A | Require replacement |
| Insufficient clamping force, allowing hose to leak | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Melted | 1 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Outer covering damaged | 1 | Suggest replacement |
| Outer covering damaged to the extent that the inner fabric is visible | A | Require replacement |
| Protective sleeves damaged | 2 | Suggest replacement of sleeves |
| Protective sleeves missing | C | Suggest replacement of sleeves |
| Restricted, affecting performance | A | Require repair or replacement |
| Restricted, not affecting performance | 2 | Suggest repair or replacement |
| Routed incorrectly | B | Suggest replacement |
| Safety clip missing | C | Require replacement |
| Spongy | 1 | Suggest repair or replacement |
| Stripped | A | Require replacement |
| Surface cracked (weather-checked) | I | Suggest repair or replacement |
| Swollen | B | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Type incorrect | 2 | Suggest repair or replacement |
LINKAGES (EXTERNAL)
| Condition | Code | Procedure |
| Components missing | C | Require replacement of missing components |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Worn to the extent that it no longer performs its intended function | A | Require repair or replacement |
LOCKING HUB ASSEMBLIES
| Condition | Code | Procedure |
| Inoperative | A | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation. |
| Loose | B | Require repair or replacement |
| Seized in any position | A | Require repair or replacement |
| NOTE |
| Inoperative includes intermittent operation. |
LOCKING HUB CONTROL KNOBS
| Condition | Code | Procedure |
| Damaged, affecting performance | A | Require replacement |
| Missing | C | Require replacement |
| Worn, affecting performance | A | Require replacement |
LUBRICANTS
| Condition | Code | Procedure |
| Additive Depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| At service interval | 3 | Suggest replacement |
| Beyond service interval | 3 | Suggest replacement |
| Burned | | Further 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 present | B | Require 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 incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Near service interval | 3 | Suggest replacement |
| Oxidized | A | Require replacement of fluid |
| Rubber master cylinder cover gasket distorted and gummy | A | Require 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
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | A | Require 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 present | B | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Rubber master/ clutch cylinder cover gasket distorted or gummy | A | Require 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 performance | | Further 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
| Condition | Code | Procedure |
| Any internal component failure that requires removal of the assembly from the vehicle for service. | A | Require 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
| Condition | Code | Procedure |
| Leaking | A | Require 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.
| Condition | Code | Procedure |
| Drive flange bent | A | Require replacement |
| Drive flange damaged, affecting performance | A | Require replacement |
| Rubber drive joint cracked | 2 | Suggest replacement |
| Rubber drive joint damaged, affecting performance | A | Require replacement |
| Rubber drive joint split between mounting holes | A | Require replacement |
| Rubber drive joint torn at mounting holes | A | Require replacement |
| Rubber drive joint weather-cracked | | No service suggested or required |
MODULATOR PINS
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Missing | C | Require replacement |
MODULATORS
| Condition | Code | Procedure |
| Bent, affecting performance | A | Require replacement |
| Contaminated (water, fuel, etc. ) | A | Require replacement |
| NOTE: Further inspection is required to determine the cause of the contamination. |
| Housing cracked | A | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking fluid externally | A | Require repair or replacement |
| Leaking fluid internally | A | Require replacement |
| Leaking vacuum | A | Require replacement |
| Nipple broken | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| NOTE |
| Further inspection is required to determine the cause of the contamination. |
| NOTE |
| Inoperative includes intermittent operation. |
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Broken | A | Require replacement |
| Leaking (hydraulic mount) | A | Require replacement |
| Mounting hole worn, affecting performance | A | Require replacement |
| Mounting hole worn, not affecting performance | | No service suggested or required |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Rubber deteriorated, not affecting performance | | No service suggested or required |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
ODOMETER DRIVES (MECHANICAL)
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking | B | Require repair or replacement |
| Missing | C | Require replacement |
| Teeth broken | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
| NOTE |
| Inoperative includes intermittent operation. |
ODOMETER HEADS (MECHANICAL)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Lens broken | A | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only. |
| Lens cloudy | 2 | Suggest repair or replacement |
| NOTE: If lens is available as a separate part, suggest replacement of lens only. |
| Lens missing | C | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only. |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range. |
| Noisy | 2 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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
| Condition | Code | Procedure |
| Bent, interfering with filter or other internal components | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
PANS
| Condition | Code | Procedure |
| Bent, interfering with filter or other internal components | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
PILOT HOLES
| Condition | Code | Procedure |
| Application incorrect | B | Require repair or replacement |
| Cracked | A | Require repair or replacement |
| Distorted | A | Require repair or replacement |
| Missing | C | Require replacement |
| Positioned incorrectly | B | Require repair or replacement |
| Stepped | A | Require repair or replacement |
| Worn to the extent that it no longer performs its intended function | A | Require repair or replacement |
PRESSURE PLATES
| Condition | Code | Procedure |
| Balance weight missing | C | Require replacement |
| Broken | A | Require replacement |
| Contact surface distorted | B | Require replacement |
| Cracks | B | Require replacement |
| Fingers bent | A | Require replacement |
| Hard spots | B | Require replacement |
| Scored | B | Require replacement |
| Spring rate less than specifications | B | Require replacement |
| Worn beyond specifications | B | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
PRESSURE SWITCHES
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Binding, affecting performance | A | Require repair or replacement |
| Binding, not affecting performance | 2 | Suggest repair or replacement |
| Broken | A | Require repair or replacement |
| Burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Cracked, affecting performance | A | Require repair or replacement |
| Cracked, not affecting performance | 1 | Suggest repair or replacement |
| Leaking | B | Require repair or replacement |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, or failure to perform all functions. |
| Melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Missing | C | Require replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Won't return | A | Require repair or replacement |
| Worn | 1 | Suggest 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.
| Condition | Code | Procedure |
| Bearing end-play exceeds specifications | B | Require adjustment of bearing, if possible If proper adjustment cannot be obtained, require replacement of bearing assembly |
| 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 assembly | B | 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 |
| 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.
| Condition | Code | Procedure |
| Drive flange bent | A | Require repair or replacement |
| Drive flange damaged, affecting performance | A | Require replacement |
| Rubber drive joint cracked | 2 | Suggest replacement |
| Rubber drive joint damaged, affecting performance | A | Require replacement |
| Rubber drive joint split between mounting holes | A | Require replacement |
| Rubber drive joint torn at mounting holes | A | Require replacement |
| Rubber drive joint weather-cracked | | No service suggested or required |
SCREENS
| Condition | Code | Procedure |
| At service interval | 3 | Suggest replacement |
| Bent, affecting performance | A | Require repair or replacement |
| Exceeding service interval | 3 | Suggest replacement |
| Missing | C | Require replacement |
| Near service interval | 3 | Suggest replacement |
| Restricted | A | Require repair or replacement |
| NOTE: Further inspection may be required to determine the source of restriction or contamination. |
| Torn | A | Require replacement |
| Worn, affecting performance (metal or nylon screen type) | A | Require repair or replacement |
| NOTE |
| Further inspection may be required to determine the source of restriction or contamination. |
SEALS (METAL CLAD)
| Condition | Code | Procedure |
| Leaking | A | Require 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
| Condition | Code | Procedure |
| Leaking | A | Require 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
| Condition | Code | Procedure |
| Binding | A | Require repair or replacement |
| Broken | A | Require repair or replacement |
| Components missing | C | Require replacement of missing components |
| Loose, affecting performance | A | Require repair or replacement |
| Out of adjustment | B | Require repair |
| Worn, affecting performance | A | Require repair or replacement |
SENSORS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation or out of specification. |
| Leaking (vacuum/fluid/air) | A | Require replacement |
| Out of adjustment | B | Further inspection required |
| NOTE: Follow OEM recommended adjustment procedures. Repair or replace if out of specification. |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| 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
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking (vacuum) | A | Require repair or replacement |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| 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
| Condition | Code | Procedure |
| Binding | A | Require repair or replacement |
| Broken | A | Require repair or replacement |
| Components missing | C | Require replacement of missing components |
| Loose, affecting performance | A | Require repair or replacement |
| Out of adjustment | B | Require repair |
| Worn, affecting performance | A | Require repair or replacement |
SIDE COVERS
| Condition | Code | Procedure |
| Bent, interfering with filter or other internal components | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
SLIP YOKES
| Condition | Code | Procedure |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn close to the end of their useful life | 1 | Suggest replacement |
| Splines worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement |
SOLENOIDS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware. |
| Attaching hardware not functioning | A | Require repair or replacement of hardware. |
| Connector (Weatherpack type) leaking | A | Require repair or replacement. |
| Connector broken | A | Require repair or replacement. |
| Connector melted, affecting performance | A | Require repair or replacement. |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement. |
| Inoperative | A | Require replacement. |
| NOTE: Inoperative includes intermittent operation. |
| Missing | C | Require replacement. |
| Noisy | 2 | Suggest repair or replacement. |
| Out of adjustment | B | Require repair or replacement. |
| Terminal broken | A | Require repair or replacement. |
| Terminal burned, affecting performance | A | Require repair or replacement. |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement. |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement. |
| Terminal corroded, not affecting performance | 1 | Suggest repair or replacement. |
| Terminal loose, affecting performance | B | Require repair or replacement. |
| Terminal loose, not affecting performance | 1 | Suggest 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)
| Condition | Code | Procedure |
| Air gap incorrect | B | Require adjustment or replacement |
| NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause. |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware threads damaged | A | Require repair or replacement of hardware |
| Attaching hardware threads stripped (threads missing) | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Contaminated | A | Require repair or replacement |
| NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement. |
| Inoperative | A | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure. |
| Leaking | B | Require repair or replacement |
| Loose | A | Require repair or replacement |
| Missing | C | Require replacement |
| Resistance out of specification | B | Require repair or replacement |
| Sensor housing cracked | 2 | Suggest replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Wire lead conductors exposed | B | Require repair or replacement |
| Wire lead corroded | A | Require repair or replacement |
| Wire lead misrouted | B | Require re-routing according to vehicle manufacturer's specifications |
| Wire lead open | A | Require repair or replacement |
| Wire lead shorted | A | Require 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
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking | B | Require repair or replacement |
| Missing | C | Require replacement |
| Teeth broken | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
| NOTE |
| Inoperative includes intermittent operation. |
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking | B | Require repair or replacement |
| Missing | C | Require replacement |
| Teeth broken | A | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn close to the end of its useful life | 1 | Suggest replacement |
| Worn, affecting performance | A | Require replacement |
| NOTE |
| Inoperative includes intermittent operation. |
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Lens broken | A | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only. |
| Lens cloudy | 2 | Suggest repair or replacement |
| NOTE: If lens is available as a separate part, suggest replacement of lens only. |
| Lens missing | C | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only. |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range. |
| Noisy | 2 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Leaking | B | Require replacement |
| Lens broken | A | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only. |
| Lens cloudy | 2 | Suggest repair or replacement |
| NOTE: If lens is available as a separate part, suggest replacement of lens only. |
| Lens missing | C | Require repair or replacement |
| NOTE: If lens is available as a separate part, require replacement of lens only . |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range. |
| Mechanical head noisy | 2 | Suggest repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| 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
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Binding, affecting performance | A | Require repair or replacement |
| Binding, not affecting performance | 2 | Suggest repair or replacement |
| Broken | A | Require repair or replacement |
| Burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Cracked, affecting performance | A | Require repair or replacement |
| Cracked, not affecting performance | 1 | Suggest repair or replacement |
| Leaking | B | Require repair or replacement |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, or failure to perform all functions. |
| Melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Missing | C | Require replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Won't return | A | Require repair or replacement |
| Worn | 1 | Suggest 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.
| Condition | Code | Procedure |
| Alignment incorrect | B | Require repair or replacement |
| Bent | B | Require replacement |
| Contaminated, affecting performance | A | Require repair. Identify and correct cause |
| Cracked | A | Require replacement |
| Loose | A | Require replacement of worn parts |
| Missing | C | Require replacement |
| Number of teeth incorrect | B | Require replacement |
| Teeth broken | A | Require replacement |
| Teeth damaged, affecting performance | A | Require replacement |
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.
| Condition | Code | Procedure |
| Alignment incorrect | B | Require repair or replacement |
| Bent | B | Require replacement |
| Contaminated, affecting performance | A | Require repair. Identify and correct cause |
| Cracked | A | Require replacement |
| Loose | A | Require replacement of worn parts |
| Missing | C | Require replacement |
| Number of teeth incorrect | B | Require replacement |
| Teeth broken | A | Require replacement |
| Teeth damaged, affecting performance | A | Require replacement |
TORQUE CONVERTERS
| Condition | Code | Procedure |
| Converter clutch lock-up operation is faulty | A | Require replacement |
| Cover shell damaged, affecting performance | A | Require replacement |
| Does not meet stall speed specification | B | Require replacement |
| End play exceeds specifications | B | Require replacement |
| Hub broken | A | Require replacement |
| Hub cracked | A | Require replacement |
| Internal component failure | A | Require replacement |
| Leaking | B | Require repair or replacement |
| Pilot broken | A | Require replacement |
| Pilot worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Weights missing | C | Require replacement |
TRANSAXLE MOUNTS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Broken | A | Require replacement |
| Leaking (hydraulic mount) | A | Require replacement |
| Mounting hole worn, affecting performance | A | Require replacement |
| Mounting hole worn, not affecting performance | | No service suggested or required |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Rubber deteriorated, not affecting performance | | No service suggested or required |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
TRANSDUCERS (TRANSMISSION)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation or out of specification. |
| Leaking (vacuum/fluid/air) | A | Require replacement |
| Out of adjustment | B | Further inspection required |
| NOTE: Follow OEM recommended adjustment procedures. Repair or replace if out of specification. |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| 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
| Condition | Code | Procedure |
| Any internal component failure that requires removal of the assembly from the vehicle for service. | A | Require 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
| Condition | Code | Procedure |
| Additive depletion | A | Require replacement of fluid |
| Application incorrect | B | Require replacement |
| NOTE: Determine and correct cause. |
| Burned | | Further 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 present | B | Require 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 present | A | Require 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 interval | 3 | Suggest replacement |
| Fluid discolored | | No service suggested or required |
| NOTE: Further testing necessary to determine condition of fluid. |
| Fluid incorrect | B | Require 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 incorrect | B | Require correction of fluid level |
| Oxidized | A | Require replacement of fluid |
| Rubber master/ clutch cylinder cover gasket distorted or gummy | A | Require 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 performance | | Further 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
| Condition | Code | Procedure |
| Air flow obstruction | A | Require repair |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connection leaking | A | Require repair or replacement |
| Contaminated | A | Require repair or replacement |
| Corroded | 1 | Suggest repair or replacement |
| Fins damaged, affecting performance | A | Require repair or replacement |
| Fins damaged, not affecting performance | | No service suggested or required |
| Internal restrictions | B | Require repair or replacement |
| Leaking | B | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require repair or replacement |
| Tubes damaged, affecting performance | A | Require repair or replacement |
| Tubes damaged, not affecting performance | | No service suggested or required |
TRANSMISSION MOUNTS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Broken | A | Require replacement |
| Leaking (hydraulic mount) | A | Require replacement |
| Mounting hole worn, affecting performance | A | Require replacement |
| Mounting hole worn, not affecting performance | | No service suggested or required |
| Rubber deteriorated, affecting performance | A | Require replacement |
| Rubber deteriorated, not affecting performance | | No service suggested or required |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
TRANSMISSION PANS
| Condition | Code | Procedure |
| Bent, interfering with filter or other Internal components | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
TRANSMISSION RANGE INDICATORS (PRNDL)
| Condition | Code | Procedure |
| Binding | A | Require repair or replacement |
| Broken | A | Require repair or replacement |
| Components missing | C | Require replacement of missing components |
| Loose, affecting performance | A | Require repair or replacement |
| Out of adjustment | B | Require repair |
| Worn, affecting performance | A | Require repair or replacement |
TUBES
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| At or beyond service interval | 3 | Suggest replacement |
| Connected incorrectly | A | Require repair |
| Corroded, not reusable | 1 | Suggest replacement |
| Cracked line or tube | A | Require replacement |
| Hard hose | 1 | Suggest replacement |
| Inner fabric (webbing) damaged | A | Require replacement |
| Insufficient clamping force, allowing hose to leak | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Melted | 1 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Outer covering damaged | 1 | Suggest replacement |
| Outer covering damaged to the extent that the inner fabric is visible | A | Require replacement |
| Protective sleeves damaged | 2 | Suggest replacement of sleeves |
| Protective sleeves missing | C | Suggest replacement of sleeves |
| Restricted, affecting performance | A | Require repair or replacement |
| Restricted, not affecting performance | 2 | Suggest repair or replacement |
| Routed incorrectly | B | Suggest replacement |
| Safety clip missing | C | Require replacement |
| Spongy | 1 | Suggest repair or replacement |
| Stripped | A | Require replacement |
| Surface cracked (weather-checked) | 1 | Suggest repair or replacement |
| Swollen | B | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Type incorrect | 2 | Suggest repair or replacement |
UNIVERSAL JOINTS (CARDAN OR CROSS TYPE)
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Bearing cap distorted | B | Require replacement |
| Binding | A | Require replacement |
| Cross (trunion) worn, affecting performance | A | Require replacement |
| Double cardan centering ball damaged | A | Require replacement |
| Double cardan centering ball worn, affecting performance | A | Require replacement |
| Double cardan centering spring broken | A | Require replacement |
| Double cardan centering spring missing | C | Require replacement |
| Double cardan centering spring weak | A | Require replacement |
| End cap seal cracked | 2 | Suggest replacement |
| End cap seal missing | C | Require replacement of seal |
| Grease fitting broken | A | Require replacement of grease fitting |
| NOTE: A broken grease fitting does not require replacement of the U-Joint. |
| Grease fitting missing | C | Require replacement of grease fitting |
| NOTE: A missing grease fitting does not require replacement of the U-Joint. |
| Rust-colored powder around end cap seals | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Worn, affecting performance | A | Require replacement |
| 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
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking (vacuum) | A | Require repair or replacement |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Require repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| 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
| Condition | Code | Procedure |
| Application incorrect | B | Require replacement |
| At or beyond service interval | 3 | Suggest replacement |
| Connected incorrectly | A | Require repair |
| Corroded, not reusable | 1 | Suggest replacement |
| Cracked line or tube | A | Require replacement |
| Hard hose | 1 | Suggest replacement |
| Inner fabric (webbing) damaged | A | Require replacement |
| Insufficient clamping force, allowing hose to leak | A | Require repair or replacement |
| Leaking | A | Require repair or replacement |
| Melted, affecting performance | B | Require repair or replacement |
| Missing | C | Require replacement |
| Outer covering damaged | 1 | Suggest replacement |
| Outer covering damaged to the extent that the inner fabric is visible | A | Require replacement |
| Protective sleeves damaged | 2 | Suggest replacement of sleeves |
| Protective sleeves missing | C | Suggest replacement of sleeves |
| Restricted, affecting performance | A | Require repair or replacement |
| Restricted, not affecting performance | 2 | Suggest repair or replacement |
| Routed incorrectly | B | Suggest replacement |
| Safety clip missing | C | Require replacement |
| Spongy | 1 | Suggest repair or replacement |
| Stripped | A | Require replacement |
| Surface cracked (weather-checked) | 1 | Suggest repair or replacement |
| Swollen | B | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Type incorrect | 2 | Suggest repair or replacement |
VACUUM MOTORS
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Inoperative | A | Require replacement |
| NOTE: Inoperative includes intermittent operation. |
| Leaking (vacuum) | A | Require repair or replacement |
| Linkage bent, affecting performance | A | Require repair or replacement of linkage |
| Linkage bent, not affecting performance | 2 | Suggest repair or replacement of linkage |
| Linkage binding, affecting performance | A | Require repair or replacement of linkage |
| Linkage binding, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage broken | A | Require repair or replacement of linkage |
| Linkage loose, affecting performance | A | Require repair or replacement of linkage |
| Linkage loose, not affecting performance | 1 | Suggest repair or replacement of linkage |
| Linkage missing | C | Require replacement |
| Linkage noisy | 2 | Suggest repair or replacement |
| Missing | C | Require replacement |
| Noisy | 2 | Suggest repair or replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| 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
| Condition | Code | Procedure |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Binding, affecting performance | A | Require repair or replacement |
| Binding, not affecting performance | 2 | Suggest repair or replacement |
| Broken | A | Require repair or replacement |
| Burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Cracked, affecting performance | A | Require repair or replacement |
| Cracked, not affecting performance | 1 | Suggest repair or replacement |
| Leaking | B | Require repair or replacement |
| Malfunctioning | A | Require repair or replacement |
| NOTE: Includes inoperative, intermittent operation, or failure to perform all functions. |
| Melted, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Melted, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Missing | C | Require replacement |
| Out of adjustment | B | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Won't return | A | Require repair or replacement |
| Worn affecting performance | B | Require 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
| Condition | Code | Procedure |
| Air gap incorrect | B | Require adjustment or replacement |
| NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause. |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware threads damaged | A | Require repair or replacement of hardware |
| Attaching hardware threads stripped (threads missing) | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Contaminated | A | Require repair or replacement |
| NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement. |
| Inoperative | B | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure. |
| Leaking | A | Require repair or replacement |
| Loose | A | Require repair or replacement |
| Missing | C | Require replacement |
| Resistance out of specification | B | Require repair or replacement |
| Sensor housing cracked | 2 | Suggest replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| Terminal corroded, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Wire lead conductors exposed | B | Require repair or replacement |
| Wire lead corroded | A | Require repair or replacement |
| Wire lead misrouted | B | Require re-routing according to vehicle manufacturer's specifications |
| Wire lead open | A | Require repair or replacement |
| Wire lead shorted | A | Require 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
| Condition | Code | Procedure |
| Broken | A | Require replacement |
| Missing | C | Require replacement |
| Plugged | A | Require 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
| Condition | Code | Procedure |
| Broken | A | Require replacement |
| Missing | C | Require replacement |
| Out of position | B | Require repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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.
| Condition | Code | Procedure |
| Bent | A | Require replacement |
| Broken | A | Require 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. |
| Loose | A | Require repair or replacement of affected component |
| Lug nut installed backward | B | Require repair or replacement |
| Lug nut mating surface dished | A | Require replacement of nut |
| Lug nut mating type incorrect | B | Require replacement of nut |
| Lug nut rounded | A | Require replacement of nut |
| NOTE: Only required if removing wheel. |
| Lug nut seized | A | Require replacement of nut |
| NOTE: Only required if removing wheel. |
| Stud incorrect | B | Require replacement of stud |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require 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
| Condition | Code | Procedure |
| Air gap incorrect | B | Require adjustment or replacement |
| NOTE: If a sensor is not adjustable, further inspection is required to identify and correct cause. |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware threads damaged | A | Require repair or replacement of hardware |
| Attaching hardware threads stripped (threads missing) | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Connector missing | C | Require replacement |
| Contaminated | A | Require repair or replacement |
| NOTE: Determine source of contamination, such as metal particles or water. Require repair or replacement. |
| Inoperative | A | Require repair or replacement |
| NOTE: Inoperative includes intermittent operation. Some components may be serviceable; check for accepted cleaning procedure. |
| Leaking | B | Require repair or replacement |
| Loose | A | Require repair or replacement |
| Missing | C | Require replacement |
| Resistance out of specification | B | Require repair or replacement |
| Sensor housing cracked | 2 | Suggest replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| Wire lead conductors exposed | B | Require repair or replacement |
| Wire lead corroded | A | Require repair or replacement |
| Wire lead misrouted | B | Require re-routing according to vehicle manufacturer's specifications |
| Wire lead open | A | Require repair or replacement |
| Wire lead shorted | A | Require 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
| Condition | Code | Procedure |
| Application incorrect | B | Require repair or replacement |
| Attaching hardware broken | A | Require repair or replacement of hardware |
| Attaching hardware missing | C | Require replacement of hardware |
| Attaching hardware not functioning | A | Require repair or replacement of hardware |
| Connector (Weatherpack type) leaking | A | Require repair or replacement |
| Connector broken | A | Require repair or replacement |
| Connector melted | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Insulation damaged, conductors exposed | A | Require repair or replacement |
| Insulation damaged, conductors not exposed | 1 | Suggest replacement |
| Open | A | Require repair or replacement |
| Protective shield (conduit) melted | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Protective shield (conduit) missing | C | Suggest repair or replacement |
| Resistance (voltage drop) out of specification | A | Require repair or replacement |
| Routed incorrectly | B | Require repair |
| Secured incorrectly | B | Require repair |
| Shorted | A | Require repair or replacement |
| Terminal broken | A | Require repair or replacement |
| Terminal burned, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal burned, not affecting performance | 2 | Suggest repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, affecting performance | A | Require repair or replacement |
| NOTE: Determine cause and correct prior to repair or replacement of part. |
| Terminal corroded, not affecting performance | 1 | Suggest repair or replacement |
| Terminal loose, affecting performance | B | Require repair or replacement |
| Terminal loose, not affecting performance | 1 | Suggest repair or replacement |
| Transmission connector leaking | See Transmission Assembly | |
| Voltage drop out of specification | A | Require repair or replacement |
| 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
| Condition | Code | Procedure |
| Bearing cap bore distorted | A | Require repair or replacement |
| Bent | A | Require replacement |
| Bolt holes elongated | A | Require repair or replacement |
| Bushing or seal surface worn, affecting performance | A | Require repair or replacement |
| Leaking through soft yoke plug | A | Require repair or replacement of soft yoke plug |
| Retainer strap bent | A | Require replacement of retainer strap |
| Slip yoke broken | A | Require replacement |
| Splines worn close to the end of their useful life | 1 | Suggest replacement |
| Splines worn, affecting performance | A | Require replacement |
| Threads damaged | A | Require repair or replacement |
| Threads stripped (threads missing) | A | Require replacement |
| U-bolt damaged, affecting performance | A | Require replacement of U-bolts |
| Yoke damaged, affecting performance | A | Require repair or replacement |
REASON CODE EXPLANATION
| Code | Reason |
| Required |
| A | Part No Longer Performs Intended Purpose |
| B | Part Does Not Meet A Design Specification ( Regardless Of Performance) |
| C | Part Is Missing |
| Suggested/Optional |
| 1 | Part Is Close To The End Of Its Useful Life |
| 2 | To Address A Customer Need, Convenience Or Request |
| 3 | To Comply With Maintenance Recommended By The Vehicle's Original Equipment Manufacturer |
| 4 | Technician's Recommendation Based On Substantial And Informed Experience |
| 5 | To Comply With Maintenance Recommended By AMRA/MAP |
AUTOMOTIVE TERMINOLOGY & DEFINITIONS