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Volvo 850 brake system checklist

Volvo 850, S70, C70 & V70 service & repair manual

BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES

1995 Volvo 850

GENERAL INFORMATION
Brake Systems – Motorist Assurance Program
Standards For Automotive Repair
All Makes & Models

CONTENTS

OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS ACCELEROMETERS (G SENSOR OR LATERAL)
ACCUMULATORS ANCHOR PINS
ANTI-LOCK BRAKE SYSTEMS BACKING PLATES
BRAKE FLUID
BRAKE FRICTION MATERIAL BRAKE PADS
BRAKE PEDALS BRAKE SHOES
BRAKE SHOE HARDWARE
BRAKE STOPLIGHT SWITCHES BULB SOCKETS
BULBS AND LEDS CALIPER HARDWARE CALIPERS CONTROLLERS
DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB) DISABLE SWITCHES
DRUMS
ELECTRICAL PUMPS AND MOTORS ELECTRONIC CONTROLLERS
FLUID
FLUID LEVEL SENSOR SWITCHES FOUR WHEEL DRIVE SWITCHES FRICTION MATERIAL
G SENSORS HOSES
HYDRAULIC MODULATORS HYDRO-BOOSTERS
HYDRO-ELECTRIC BOOSTERS (POWERMASTER) IGNITION DISABLE SWITCHES
LATERAL ACCELERATION SWITCHES LEDS
LENSES
MASTER CYLINDERS MODULATORS
MOTORS
PARKING BRAKE SWITCHES PARKING BRAKE SYSTEMS PADS
PEDAL TRAVEL SWITCHES PEDALS
POWERMASTER PUMPS
PRESSURE DIFFERENTIAL SWITCHES PRESSURE SWITCHES
RELAYS ROTORS
SELF-ADJUSTING SYSTEMS
SHOE HARDWARE SHOES
SOCKETS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) STEEL BRAKE LINES
STOPLIGHT SWITCHES SWITCHES
TIRES
TOOTHED RINGS (TONE WHEEL) VACUUM BOOSTERS
VACUUM HOSES VALVES
WHEEL ATTACHING HARDWARE
WHEEL BEARINGS, RACES AND SEALS WHEEL CYLINDERS
WIRING HARNESSES

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.
Our organization’s mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper, manufacturer-recommended, maintenance. We encourage participating
service and repair shops (including franchisees and dealers) to adopt:
1) a Pledge of Assurance to their Customers and
2) the Motorist Assurance Program Standards of Service.
All participating service providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.
These Standards of Service require that an inspection of the vehicle’s (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection communication standards are continually re-published. In addition to these, standards for
Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication Standards as part of the inspection process and for communicating their findings to their customers.
The Motorist Assurance Program continues to work cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not
satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other non- profit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating
the results of their inspection to their customers. To put some “teeth” in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the “mystery shopping” of outlets.
We welcome you to join us as we continue our outreach with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646
January 1999

MAP UNIFORM INSPECTION GENERAL GUIDELINES

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

It is MAP policy that all exhaust, brake, steering, suspension, wheel alignment, drive-line, engine performance and maintenance, and heating, ventilation and air conditioning, and electrical services be offered and performed under the standards and procedures specified in these sections.
Before any service is performed on a vehicle, an inspection of the appropriate system must be performed. The results of this inspection must be explained to the customer and documented on an inspection form. The condition of the vehicle and its components will indicate what services/part replacements may be “Required” or “Suggested”. In addition, suggestions may be made to satisfy the requests expressed by the customer.
When a component is suggested or required to be repaired or replaced, the decision to repair or replace must be made in the customer’s best interest, and at his or her choice given the options available.
This section lists the various parts and conditions that indicate a required or suggested service or part replacement. Although this list is extensive, it is not fully inclusive. In addition to this list, a technician may make a suggestion. However,
any suggestions must be based on substantial and informed experience, or the vehicle manufacturer’s recommended service interval and must be documented.
Some conditions indicate that service or part replacement is required because the part in question is no longer providing the function for which it is intended, does not meet a vehicle manufacturer’s design specification or is missing.

Example:
An exhaust pipe has corroded severely and has a hole in it through which exhaust gases are leaking. Replacement of the exhaust pipe in this case is required due to functional failure.

Example:
A brake rotor has been worn to the point where it measures less than the vehicle manufacturer’s discard specifications.
Replacement of the rotor is required because it does not meet design specifications.
Some conditions indicate that a service or part replacement is suggested because the part is close to the end of its useful life or addresses a customer’s need, convenience or request. If a customer’s vehicle has one of these conditions, the procedure may be only to suggest service.

Example:
An exhaust pipe is rusted, corroded or weak, but no leaks are present. In this case, the exhaust pipe has not failed. However, there is evidence that the pipe may need replacement in the near future. Replacement of the pipe may be suggested for the customer’s convenience in avoiding a future problem.

Example:
The customer desires improved ride and/or handling, but the vehicle’s shocks or struts have not failed. In this case, replacement may be suggested to satisfy the customer’s
wishes. In this case, replacement of the shocks or struts may not be sold as a requirement.
A customer, of course, has the choice of whether or not a shop will service his or her vehicle. He or she may decide not to follow some of your suggestions. When a repair is required, a MAP shop must refuse partial service on that system if, in the judgment of the service provider, proceeding with the work could create or
continue an unsafe condition. When a procedure states that required or suggested repair or replacement is recommended, the customer must be informed of the generally acceptable repair/replacement options whether or not performed by the shop.
When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.
The following reasons may be used for required and suggested services. These codes are shown in the “Code” column of the MAP Uniform Inspection & Communications Standards that follow:
Reasons to Require Repair or Replacement
A – Part no longer performs intended purpose
B – Part does not meet a design specification (regardless of performance)
C – Part is missing
NOTE: When a repair is required, the shop must refuse partial service to the system in question, if the repair creates or continues an unsafe condition.
Reasons to Suggest Repair or Replacement
1 – Part is close to the end of its useful life (just above discard specifications, or weak; failure likely to occur soon, etc.)
2 – To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.)
3 – To comply with maintenance recommended by the vehicle’s
Original Equipment Manufacturer (OEM)
4 – Technician’s recommendation based on substantial and informed experience
NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions and make an informed decision about how to proceed.

BRAKES

SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER

VEHICLE OPERATION
Some states may have specifications that differ from OEM. Check your local/state regulations. Where state or local laws are stricter, they take precedence over these guidelines.

ACCELEROMETERS (G SENSOR OR LATERAL)

ACCELEROMETER INSPECTION
Condition Code Procedure
Broken ……………… A ………… Require replacement. Connector loose ……… A .. Require repair or replacement. Loose ………………. B .. Require repair or replacement. Missing …………….. C ………… Require replacement. Out of position ……… B ……. Require re-positioning to vehicle manufacturer’s
specifications. Output signal incorrect . B ………… Require replacement.

ACCUMULATORS

ACCUMULATOR INSPECTION
Condition Code Procedure
Leaking …………….. B ………… Require replacement. Missing …………….. C ………… Require replacement. Pre-charge incorrect …. B ………… Require replacement.

ANCHOR PINS

See BACKING PLATES.

ANTI-LOCK BRAKE SYSTEMS

NOTE: Anti-lock brakes are an integral part of the brake system. It is essential that the anti-lock brakes function properly when brake service is performed.
Anti-lock brake systems are commonly referred to as “ABS” and will be referred to as “ABS” throughout these guidelines. Some ABS components also function as part of a traction control system (TCS).
WARNING: When diagnosing and servicing high pressure components, observe safety procedures and equipment requirements established by the vehicle manufacturer to reduce the possibility of serious personal injury.
NOTE: Intermittent electrical conditions are often caused by a loss of ground, poor connection, or water intrusion into the
wiring harness.
NOTE: Electro-magnetic interference (EMI) may be caused by incorrect installation of accessories or components. EMI can result in improper system operation.

BACKING PLATES

BACKING PLATE INSPECTION
Condition Code Procedure

Anchor pin bent ………

B

.. Require repair or

replacement.

Anchor pin broken …….

A

………… Require

replacement.

Anchor pin worn, affecting

structural integrity …

B

………… Require

replacement.

Backing plate bent ……

B

.. Require repair or

replacement.

Backing plate broken ….

A

………… Require

replacement.

Backing plate cracked …

B

.. Require repair or

replacement.

Corroded, affecting

structural integrity ….

A

………… Require

replacement.

Loose ……………….

B

.. Require repair or

replacement.

Missing ……………..

C

………… Require

replacement.

Shoe lands worn ………

A

.. Require repair or

replacement.

BRAKE FLUID

CAUTION: Most manufacturers prohibit the use of DOT 5 brake fluid in a system equipped with ABS.
DOT 3, DOT 4, and DOT 5.1 brake fluids are clear or light amber in color. DOT 5 brake fluid is violet in color. Correct fluid required for the brake system is stamped on the master cylinder cover.
BRAKE FLUID INSPECTION
Condition Code Procedure
Beyond service interval . 3 .. Suggest flushing and refilling with correct fluid.
Brake fluid type
incorrect ………….. B .. Require flushing and refilling with correct fluid.
Contaminated, for example, fluid other than brake
fluid present ………. A or B ……. (1) Require service. Hydraulic component ….. 3 .. Suggest flushing and refilling overhaul or replacement with correct fluid. Rubber master cylinder
cover gasket distorted
and gummy ………….. A ………. (2) Require replacement of gasket.
(1) – If a fluid other than brake fluid is present in the brake system which DOES affect the rubber parts, the required service is to:
* Remove all components having rubber parts from the system.
* Flush lines with denatured alcohol or brake cleaner
* Repair or replace all components having rubber parts
* Flush and fill with correct brake fluid. (Code A)
If a fluid other than brake fluid is present in the brake
system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct brake fluid. (Code B)
(2) – This condition may indicate contaminated brake fluid.

BRAKE FRICTION MATERIAL

See FRICTION MATERIAL.

BRAKE PADS

See FRICTION MATERIAL.

BRAKE PEDALS

BRAKE PEDAL INSPECTION
Condition Code Procedure
Bent, affecting
performance ………… A .. Require repair or replacement. Broken ……………… A .. Require repair or replacement.

Pedal pad missing …….

C

…. Require

replacement of pedal

pad.

Pedal pad worn ……….

1

…………

Suggest replacement.

Pivot bushings worn,

affecting performance ..

A

…. Require

replacement of pivot

bushings.

BRAKE SHOES

See FRICTION MATERIAL.

BRAKE SHOE HARDWARE

See also SELF-ADJUSTING SYSTEMS. BRAKE SHOE HARDWARE INSPECTION
Condition Code Procedure

Broken ……………… A

…………

Require

replacement.

Distorted …………… A

…………

Require

replacement.

Missing …………….. C

…………

Require

replacement.

Surfaces rust-pitted …. 1

…………

Suggest

replacement.

Worn, affecting

performance ………… A

…………

Require

replacement.

BRAKE STOPLIGHT SWITCHES

BRAKE STOPLIGHT INSPECTION
Condition Code Procedure
Bent ……………….. B ………… Require replacement. Broken ……………… A ………… Require replacement. Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement.
Connector melted …….. A …….. (1) Require replacement. Connector missing ……. C ………… Require replacement. Missing …………….. C ………… Require replacement. Out of adjustment ……. B ……….. Require adjustment or replacement.
Output signal incorrect . B ………… Require replacement. Terminal burned, affecting
performance ………… A ………….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance … A .. Require repair or replacement. Terminal corroded, not
affecting performance … 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance … 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
(1) – Determine cause and correct prior to replacement of part. (2) – Determine cause and correct prior to repair or replacement
of part.

BULB SOCKETS

Attaching hardware
Attaching hardware not
Corroded, affecting
performance ………… A .. Require repair or replacement. Corroded, not affecting

performance …………

2

.. Suggest repair or

replacement.

Leaking ……………..

A

.. Require repair or

replacement.

Melted ………………

A

…….. (2) Require

replacement.

Shorted ……………..

A

.. Require repair or replacement.

Terminal broken ………

A

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

………….. (2) Require repair

or replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of socket.
(2) – Determine cause and correct prior to repair or replacement of part.

BULBS AND LEDS

NOTE: Copied from Electrical UIGs and modified. Does not include soldered-in components.
BULB AND LED INSPECTION
Condition Code Procedure
Application incorrect … B …….. (1) Require replacement. Base burned, affecting
performance ………… A ………….. (2) Require repair or replacement.
Base burned, not affecting
performance ………… 2 ………….. (2) Suggest repair or replacement.
Base corroded, affecting
performance ………… A .. Require repair or replacement. Base corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Base loose, affecting
performance ………… B .. Require repair or replacement. Base loose, not affecting
performance ………… 1 .. Suggest repair or replacement. Burned out ………….. A ………… Require replacement. Intermittent ………… A ………… Require replacement. Missing …………….. C ………… Require replacement. Seized in socket …….. A .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ………….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 ………….. (2) Suggest repair or replacement.
Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement.
Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Application incorrect includes wrong bulb coating or color.
(2) – Determine cause and correct prior to repair or replacement of part.

CALIPER HARDWARE

CALIPER HARDWARE INSPECTION
Condition Code Procedure

Bent ……………….

A

..

Require

repair

or

replacement.

Broken ………………

A

..

Require

repair

or

replacement.

Corroded, affecting

performance …………

A

..

Require

repair

or

replacement.

Dust boots on slider pin
(bolt) missing ……… C … Require replacement of boots. Dust boots on slider pin
(bolt) torn ………… A … Require replacement of boots. Missing …………….. C ………… Require replacement. Shim bent …………… A …………. (1) Require removal or replacement.
Shim (OE standard)
missing ……………. C …….. (2) Require replacement. Shim out of position …. B …………. (1) Require removal or replacement.
Shim worn …………… A …………. (1) Require removal or replacement.
Slider pin (bolt) bent .. B … Require replacement of slider pin or bolt and lubricants.
Slider pin (bolt)
rust-pitted ………… A … Require replacement of slider pin or bolt and lubricants.
Slider pin (bolt) worn .. A … Require replacement of slider pin or bolt and lubricants.
Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Worn, affecting
performance ………… A ………… Require replacement.
(1) – Removal is acceptable if shim is not OE.
(2) – Aftermarket shims may be suggested to reduce noise.

CALIPERS

You are not required to replace or rebuild calipers in axle sets. However, when replacing or rebuilding a caliper due to the conditions that follow, you may suggest servicing, rebuilding, or replacement of the other caliper (on the same axle) for improved performance and preventive maintenance (for example, the part is close to the end of its useful life, replacing the caliper may extend pad life, or contribute to more balanced braking).
CAUTION: When installing loaded calipers, it is required that friction material be matched in axle sets for consistent braking characteristics.
CALIPER INSPECTION
Condition Code Procedure
Bleeder port damaged …. A … Require repair or replacement of caliper.
Bleeder screw broken off
in caliper …………. A ……….. (1) Require repair or replacement of caliper.
Mounting pin threads stripped in caliper bracket (threads
missing) …………… A … Require repair or replacement of caliper bracket.
Mounting pin threads stripped in steering knuckle (threads
missing) …………… A … Require repair or replacement of steering knuckle.
Mounting pin threads stripped (threads
missing) …………… A … Require repair or replacement of component with stripped threads.
Parking brake cable support, lever, or return
spring bent ………… A … Require replacement of parts. Parking brake cable
support, lever, or return
spring broken ………. A … Require replacement of parts. Parking brake mechanism in
caliper inoperative …. A .. Require repair or replacement. Piston corroded (pitted
or peeling chrome
plating) …………… B … Require replacement of piston and rebuilding or replacement of caliper.
Piston damaged, affecting
performance ………… B … Require replacement of piston and rebuilding or replacement of caliper.
Piston damaged, not
affecting performance .. .. …….. No service suggested or required.
Piston finish worn off .. B … Require replacement of piston and rebuilding or replacement
of caliper. Piston sticking ……… A ……….. Require rebuilding or replacement of caliper.
Slide mechanism
sticking …………… A … Require repair or replacement of slide mechanism.
(1) – Only required if the hydraulic system must be opened. (2) – Seized is defined as a bleeder screw that cannot be
removed after a practical attempt at removing. Only required if the hydraulic system must be opened.

CONTROLLERS

See ELECTRONIC CONTROLLERS.

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)

DIGITAL RATIO AXLE CONTROLLER AND BUFFER INSPECTION
Condition Code Procedure

Connector broken ……..

A

..

Require repair or

replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or

replacement.

Connector melted ……..

A

…….. (1) Require replacement.

Connector missing …….

C

………… Require replacement.

Missing ……………..

C

………… Require replacement.

Output signal incorrect .

B

.. Require repair or replacement.

Terminal burned, affecting

performance …………

A

………….. (2) Require repair

or replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to replacement of part. (2) – Determine cause and correct prior to repair or
replacement of part.

DISABLE SWITCHES

See SWITCHES.

DRUMS

Determine the need to recondition based upon individual drum conditions that follow. Friction material replacement does not require drum reconditioning unless other justifications exist. DO NOT recondition new drums unless they are being pressed or bolted onto an existing hub. It is not necessary to replace drums in axle sets. However, when replacing or reconditioning a drum due to the conditions that follow, you may suggest reconditioning of the other drum on the
same axle to eliminate uneven braking behavior. Always wash drums after servicing or before installing.
DRUM INSPECTION
Condition Code Procedure
Balance weight missing .. .. …….. No service suggested or required.
Bell-mouthed, affecting
performance ………… A ……. Require reconditioning or replacement.
Cooling fin broken …… .. …….. No service suggested or required.
Cracked …………….. B ………… Require replacement. Drum diameter is greater
than OEM “machine to” specifications but less than “discard at” specifications, and the drum does not require
reconditioning ……… 1 …….. (1) Suggest replacement. Drum diameter will exceed
OEM “machine to” specifications after required
reconditioning ……… B …….. (2) Require replacement. Hard-spotted ………… 2 ……. Suggest reconditioning or replacement.
Measured diameter is greater than OEM discard
specifications ……… B ………… Require replacement. Out-of-round (runout),
affecting performance .. A ……. Require reconditioning or replacement.
Out-of-round (runout), exceeding manufacturer’s
specifications ……… B ……. Require reconditioning or replacement.
Scored ……………… B ……. Require reconditioning or replacement.
Surface threaded due to
improper machining ….. B ……. Require reconditioning or replacement.
Tapered, affecting
performance ………… A ……. Require reconditioning or replacement.
(1) – Only applies to vehicles for which OEM “machine to” specifications exist. If OEM does not supply “machine to” specifications, the drum may be worn to discard specifications.
(2) – If OEM does not supply “machine to” specifications, you may machine to discard specifications.

ELECTRICAL PUMPS AND MOTORS

Copied fuel pump conditions from engine UIGs & deleted pulsator from leaking conditions.
ELECTRICAL PUMP AND MOTOR INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead open ………. A .. Require repair or replacement. Wire lead shorted ……. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Determine source of contamination. Require repair or replacement.
(3) – Inoperative includes intermittent operation or out of OEM
specifications.

ELECTRONIC CONTROLLERS

ELECTRONIC CONTROLLER INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Attaching hardware
missing ……………. C ………. Require replacement of
Attaching hardware threads
hardware.
damaged ……………. A … Require repair or replacement of hardware.
Attaching hardware threads stripped (threads
missing) …………… A … Require repair or replacement of hardware.
Code set (if
applicable) ………… A ………. (1) Further inspection required.
Connector broken …….. A .. Require repair or replacement. Connector melted …….. A ……….. (2) Require repair or replacement.
Connector missing ……. A …………….. Require repair. Contaminated ………… A .. Require repair or replacement. Inoperative …………. B .. Require repair or replacement. (3) Further inspection required.
Leaking …………….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (2) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement. Wire lead conductors

exposed …………….

B

.. Require repair or

replacement.

Wire lead corroded ……

A

.. Require repair or

replacement.

Wire lead open ……….

A

.. Require repair or

replacement.

Wire lead shorted …….

A

.. Require repair or

replacement.

(1) – Refer to manufacturer’s diagnostic trouble code procedure and require repair or replacement of affected component(s).
(2) – Determine cause and correct prior to repair or replacement of part.
(3) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable. Check for accepted cleaning procedure.

FLUID

See BRAKE FLUID.

FLUID LEVEL SENSOR SWITCHES

See SWITCHES.

FOUR WHEEL DRIVE SWITCHES

See SWITCHES.

FRICTION MATERIAL

NOTE: Original Equipment Manufacturer (OEM) specifications designate replacement at different thicknesses.
CAUTION: It is required that friction material be matched in axle sets for consistent braking characteristics.
FRICTION MATERIAL INSPECTION
Condition Code Procedure
Contaminated, for example, fluid that leaked from caliper, wheel cylinder,
or axle seal ……….. A …….. (1) Require replacement. Cracked through ……… B Require replacement. Flaking or chunking ….. B Require replacement. Glazed (shiny) ………. .. …….. No service suggested or required.
Grooves or ridges ……. .. …. (2) No service suggested or required.
Permanently attached
hardware bent ………. A ………… Require replacement. Permanently attached
hardware broken …….. A ………… Require replacement. Permanently attached
hardware loose ……… A ………… Require replacement. Permanently attached
hardware missing ……. C ………… Require replacement. Permanently attached
hardware seized …….. A .. Require repair or replacement. Rivets loose ………… B ………… Require replacement. Separating from backing . B ………… Require replacement. Shoe table or web bent .. B ………… Require replacement. Shoe table or web
cracked ……………. A ………… Require replacement. Shoe table or web worn,
affecting performance .. A ………… Require replacement. Surface cracking …….. .. …….. No service suggested or required. Further inspection
may be necessary to determine cause.
Tapered wear ………… B …….. (3) Suggest replacement. Thickness of one pad is
greater than opposite pad in the same caliper
(uneven wear) ………. .. …. (4) Replacement of friction material not suggested or required. Further inspection required. See CALIPERS
and CALIPER HARDWARE.
Wear indicator device
(electronic) contacts
rotor ……………… B …… (5) Require replacement of appropriate parts.
Wear indicator device
(mechanical) bent ……. .. ………. (6) Further inspection required.
Wear indicator device
(mechanical) broken …. .. ……… (6) Further inspection required.
Wear indicator device
(mechanical) contacts
rotor ……………… .. ……… (6) Further inspection required.
Worn close to minimum
specifications ……… 1 …….. (7) Suggest replacement. Worn to, or below minimum
specifications ……… B ………… Require replacement.
(1) – Identify and repair cause of contamination prior to replacing friction material.
(2) – When reconditioning or replacing drums or rotors, replacement of friction material may be suggested depending on the severity of the grooves or ridges.
(3) – Some vehicles use pads that are tapered by design. Refer to specific vehicle application. If not normal, require replacement of pads and correction of cause.
(4) – Uneven pad thickness is normal on some vehicles. Refer to specific vehicle applications.
(5) – The pad wear indicator light may come on due to other electrical problems.
(6) – Explain to the customer that the purpose of the wear indicator is to alert him or her to check for friction wear. Wear indicators may be bent or broken. Therefore, the friction material must be measured. The need for friction material replacement is determined based upon
the conditions stated in this section. Periodic inspection is suggested.
(7) – When the part appears to be close to the end of its useful life, replacement may be suggested.

G SENSORS

See ACCELEROMETERS.

HOSES

HOSE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning …………. A … Require repair or replacement of hardware.
Blistered …………… B ………… Require replacement. Fitting threads damaged . A .. Require repair or replacement. Fitting threads stripped
(threads missing) …… A ………… Require replacement. Incorrectly secured ….. B …………….. Require repair. Inner fabric
(webbing) cut ………. B ………… Require replacement. Leaking …………….. A ………… Require replacement. Missing …………….. C ………… Require replacement. Outer covering is cracked
to the extent that inner fabric of hose
is visible …………. B ………… Require replacement. Restricted ………….. A ………… Require replacement. Routed incorrectly …… B …………….. Require repair.

HYDRAULIC MODULATORS

NOTE: Many modulators can only be replaced as complete assemblies. Whenever possible, replace the failed component part. If replacement of the failed part is not possible, then replace the modulator assembly.
HYDRAULIC MODULATOR INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A …….. (1) Require replacement. Connector missing ……. C ………… Require replacement. Disabled ……………. A .. Require repair or replacement. Electrical failure …… A .. Require repair or replacement. External leak ……….. A .. Require repair or replacement. Housing cracked ……… B .. Require repair or replacement. Inoperative (2) ……… A .. Require repair or replacement. Internal leak ……….. A .. Require repair or replacement. Missing …………….. C ………… Require replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Threads damaged ………

A

..

Require

repair

or

replacement.

Threads stripped (threads

missing) …………… A ………… Require replacement.

Valve stuck ………….

A

..

Require

repair or

replacement.

Wire lead burned ……..

A

..

Require

repair or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair or

replacement.

Wire lead open ……….

A

..

Require

repair or

replacement.

Wire lead shorted …….

A

..

Require

repair or

replacement.

(1) – Determine cause and correct prior to replacement of part. (2) – Inoperative includes intermittent operation or out of OEM
specification.

HYDRO-BOOSTERS

NOTE: Hydro-boosters and hydro-electric boosters are combined.
Attaching hardware
Attaching hardware not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.
(1) – Determine cause and correct prior to replacement of part.

HYDRO-ELECTRIC BOOSTERS (POWERMASTER)

See HYDRO-BOOSTERS.

IGNITION DISABLE SWITCHES

See SWITCHES.

LATERAL ACCELERATION SWITCHES

See ACCELEROMETERS.

LEDS

See BULBS AND LEDS.

LENSES

LENSE INSPECTION
Condition Code Procedure
Application incorrect … A ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Broken, affecting
performance ………… A ………… Require replacement. Broken, not affecting
performance ………… .. …….. No service suggested or

required.

Cracked ……………..

A

…………

Require

replacement.

Discolored …………..

A

…………

Require

replacement.

Leaking ……………..

A

.. Require repair or

replacement.

Melted, affecting

performance …………

A

………… Require

replacement.

Melted, not affecting

performance …………

2

…………

Suggest

replacement.

Missing ……………..

C

…………

Require

replacement.

MASTER CYLINDERS

MASTER CYLINDER INSPECTION
Condition Code Procedure
Brake fluid leaking from rear of master cylinder
bore ………………. B .. Require repair or replacement. Brake pedal drops
intermittently ……… A ……….. (1) Require repair or replacement.
Fluid level low ……… .. ……… (2) Further inspection required.
Internal valve failure .. A .. Require repair or replacement. Master cylinder leaking
brake fluid internally . A .. Require repair or replacement. Piston does not return .. A .. Require repair or replacement. Ports plugged ……….. A .. Require repair or replacement. Rubber master cylinder
cover gasket distorted
and gummy ………….. A .. (3) Require replacement of the gasket.
(1) – This condition may be normal on some vehicles equipped with anti-lock brakes.
(2) – Refer to OEM procedures for adjusting low fluid level.
Inspect for brake hydraulic system leaks and friction material wear.
(3) – This condition may indicate contaminated brake fluid.
See BRAKE FLUID.

MODULATORS

See HYDRAULIC MODULATORS.

MOTORS

See ELECTRICAL PUMPS AND MOTORS.

PARKING BRAKE SWITCHES

See SWITCHES.

PARKING BRAKE SYSTEMS

NOTE: The parking brake is an integral part of the brake system. It is important that the parking brake function properly when brake service is performed.
PARKING BRAKE SYSTEM INSPECTION
Attaching hardware
Attaching hardware not
Cable improperly
adjusted …………… B ……. Require cable adjustment. Cable or individual
wires in the cable
are broken …………. A …. Require replacement of cable assembly.
Cable sticking ………. A …… Require cable lubrication. Cable stuck inside conduit
and cannot be lubricated so that parking brake
functions properly ….. A …. Require replacement of cable assembly.
Inoperative (1) ……… A ………. Require replacement of inoperative parts.
Parking brake
parts bent …………. B … Require repair or replacement of bent parts.
Parking brake
parts broken ……….. A … Require replacement of broken parts.
Parking brake parts
missing ……………. C .. Require replacement of missing parts.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

(1) – Inoperative includes intermittent operation.

PADS

See FRICTION MATERIAL.

PEDAL TRAVEL SWITCHES

See SWITCHES.

PEDALS

See BRAKE PEDALS.

POWERMASTER

See HYDRO-BOOSTERS.

PUMPS

See ELECTRICAL PUMPS AND MOTORS.

PRESSURE DIFFERENTIAL SWITCHES

See SWITCHES.

PRESSURE SWITCHES

See SWITCHES.

RELAYS

NOTE: Copied from Electrical UIGs
RELAY INSPECTION
Attaching hardware
Attaching hardware not
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Inoperative includes intermittent operation or out of OEM
specification.
(2) – Determine cause and correct prior to repair or replacement of part.

ROTORS

Determine the need to recondition based upon individual rotor conditions that follow. Friction material replacement does not require rotor reconditioning unless other justifications exist. DO NOT recondition new rotors unless they are being pressed or bolted onto an existing hub. It is not necessary to replace rotors in axle sets. However, when replacing or reconditioning a rotor due to the
conditions that follow, you may suggest reconditioning of the other rotor on the same axle to eliminate uneven braking behavior.
Determine the need to replace based upon the individual rotor conditions that follow. Reconditioning is defined as machining and block sanding, or block sanding only. Block sanding is defined as
using 120-150 grit sandpaper with moderate to heavy force for 60 seconds per side. Always wash rotors after servicing or before installing.
ROTOR INSPECTION
Condition Code Procedure
Corrosion affecting
structural integrity … A …….. (1) Require replacement. Cracked …………….. B ………… Require replacement. Hard spots ………….. 2 ……. Suggest reconditioning or replacement of rotor according
to OEM specifications.
Lateral runout (wobble)
exceeds OEM
specifications ……… B ………… Require re-indexing, reconditioning, or replacement according to specifications.
Measured thickness is less than OEM discard
specifications ……… B ………… Require replacement. Rotor thickness is less
than OEM “machine to” specifications but thicker than “discard at” specifications, and the rotor does not require
reconditioning ……… 1 …….. (2) Suggest replacement. Rotor thickness will be
less than OEM “machine to” specifications after required
reconditioning ……… B …….. (3) Require replacement. Surface is rust-pitted .. B ……. Require reconditioning or replacement of rotor according
to OEM specifications. Surface is scored ……. B … (4) Require reconditioning or replacement of rotor according
to OEM specifications.
Thickness variation
(parallelism) exceeds OEM
specifications ………. B ……. Require reconditioning or replacement of rotor according to OEM specifications.
(1) – Examples of severe corrosion are: composite plate separated from friction surfaces and cooling fins cracked or missing.
(2) – Only applies to vehicles for which OEM “machine to” specifications exist. If OEM does not supply “machine to” specifications, the rotor may be worn to discard specifications.
(3) – If OEM does not supply “machine to” specifications, you may machine to discard specifications.
(4) – Scoring is defined as grooves or ridges in the friction contact surface. Some vehicle manufacturers require machining when scoring exceeds their allowable specifications.

SELF-ADJUSTING SYSTEMS

SELF-ADJUSTING SYSTEM INSPECTION
Condition Code Procedure

Bent ………………..

A

Require

repair or replacement

of bent part.

Broken ………………

A

Require

repair or replacement

of broken part.

Inoperative ………….

A

……….. (1) Require repair or

replacement of inoperative

parts.

Missing ……………..

C

………. Require replacement of

missing part.

Star wheel does not turn

freely ……………..

A

.. Require repair or replacement.

(1) – Inoperative includes intermittent operation.

SHOE HARDWARE

See BRAKE SHOE HARDWARE.

SHOES

See FRICTION MATERIAL.

SOCKETS

See BULB SOCKETS.

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

NOTE: Copied Vehicle Speed Sensors from Engine UIGs & added Air Gap incorrect, loose, and wire lead misrouted. For “contaminated” removed coolant & fuel examples from note.
SPEED SENSOR INSPECTION
Condition Code Procedure
Air gap incorrect ……. B ……. (1) Require adjustment or replacement.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware
threads damaged …….. A … Require repair or replacement of hardware.
Attaching hardware

threads stripped

(threads missing) ……

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ………..

A

..

Require repair or replacement.

Connector melted ……..

A

………..

(2) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Contaminated

…………

A

……….. (3) Require repair or

replacement.

Inoperative

………….

B

……….. (4) Require repair or

replacement. Further

inspection required.

Lead routing

incorrect ..

B

….. Require rerouting according

to vehicle manufacturer’s

specifications.

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

……….. (2) Require repair or

replacement.

Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose,
affecting performance .. B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Threads damaged ……… A .. Require repair or replacement. Threads stripped
(threads missing) …… A ………… Require replacement. Wire lead conductors
exposed ……………. B .. Require repair or replacement. Wire lead corroded …… A .. Require repair or replacement. Wire lead 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.
(1) – If a sensor is not adjustable, further inspection is required to identify and correct cause.
(2) – Determine cause and correct prior to repair or replacement of part.
(3) – Determine source of contamination, such as metal particles or water. Require repair or replacement.
(4) – Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

STEEL BRAKE LINES

STEEL BRAKE LINE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Corroded, affecting
structural integrity … A ………… Require replacement. Fitting incorrect (for

example, compression

fitting) ……………

B

………… Require

replacement.

Flare type incorrect ….

B

.. Require repair or

replacement.

Leaking ……………..

A

.. Require repair or

replacement.

Line material incorrect

(copper, etc.) ………

B

………… Require

replacement.

Restricted …………..

A

………… Require

replacement.

Routed incorrectly ……

B

….. Require routing correction.

Rust-pitted ………….

1

………… Suggest replacement.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped

(threads missing) ……

A

………… Require replacement.

STOPLIGHT SWITCHES

See BRAKE STOPLIGHT SWITCHES.

SWITCHES

NOTE: Copied from Electrical UIGs & added “float saturated” from old fluid level sensor switches.
STEEL BRAKE LINE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding, affecting
performance ………… A .. Require repair or replacement. Binding, not affecting
performance ………… 2 .. Suggest repair or replacement. Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Cracked, affecting
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or replacement. Float saturated ……… A ………… Require replacement. Leaking …………….. A .. Require repair or replacement. Malfunctioning ………. A ……….. (2) Require repair or replacement.
Melted, affecting
performance ………… A ……….. (1) Require repair or replacement.
Melted, not affecting
performance ………… 2 ……….. (1) Suggest repair or replacement.
Missing …………….. C ………… Require replacement. Out of adjustment ……. B .. Require repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Won’t return ………… A .. Require repair or replacement. Worn ……………….. 1 ………… Suggest replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Includes inoperative, intermittent operation, or failure to perform all functions.

TIRES

Consult the vehicle owner’s manual or vehicle placard for correct size, speed ratings, and inflation pressure of the original tires.
TIRE INSPECTION
Tire pressure incorrect,
Tire size incorrect,

TOOTHED RINGS (TONE WHEEL)

NOTE: Copied from Drivetrain UIGs.
If the toothed ring requires replacement and cannot be replaced as a separate component, replace the assembly of which the ring is a part.
TOOTHED RING INSPECTION
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.

VACUUM BOOSTERS

VACUUM BOOSTER INSPECTION
Condition Code Procedure
Applies too much assist
(oversensitive) …….. A ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Auxiliary vacuum pump
inoperative ………… A ……….. (1) Require repair or replacement.
Check valve grommet deteriorated, affecting
performance ………… A .. Require replacement of grommet.
Check valve grommet deteriorated, not
affecting performance .. 1 . Suggest replacement of grommet. Check valve inoperative . A ……….. (2) Require repair or replacement.
Check valve leaking ….. A …. Require replacement of check valve.
Check valve missing ….. C …. Require replacement of check valve.
Check valve noisy ……. 2 ………… Suggest replacement. Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A …….. (3) Require replacement. Connector missing ……. C ………… Require replacement. Leaking …………….. A ………… Require replacement. Terminal burned, affecting
performance ………… A ……….. (3) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
missing) …………… A ………… Require replacement. Vacuum hose filter
leaking ……………. A .. Require replacement of filter. Vacuum hose filter
restricted …………. A .. Require replacement of filter.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

(1) – Inoperative includes intermittent operation or out of
OEM specification.
(2) – Inoperative includes intermittent operation.
(3) – Determine cause and correct prior to replacement of part.

VACUUM HOSES

See HOSES.

VALVES

VALVE INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of
Attaching hardware
hardware.
not functioning …….. A … Require repair or replacement of hardware.
Leaking …………….. B .. Require repair or replacement. Linkage bent (rear
load valves) ……….. A … Require repair or replacement of linkage.
Linkage broken (rear
load valves) ……….. A … Require repair or replacement of linkage.
Linkage disconnected
(rear load valves) ….. C … Require repair or replacement of linkage.
Pressure out of
specification ………. B …… Require adjustment. If not possible, require replacement.
Seized ……………… A ………… Require replacement. Sticking ……………. A .. Require repair or replacement. Terminal burned,
affecting performance .. A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,

affecting performance

..

A

..

Require

repair

or

replacement.

Terminal corroded, not

affecting performance

..

2

..

Suggest

repair

or

replacement.

Terminal loose, affecting

performance …………

B

..

Require

repair

or

replacement.

Terminal loose, not

affecting performance ..

1

..

Suggest

repair

or

replacement.

Threads damaged ………

A

..

Require

repair

or

replacement.

Threads stripped (threads

missing) …………… A ………… Require replacement.

Wire lead burned ……..

A

..

Require

repair

or

replacement.

Wire lead conductors

exposed …………….

B

..

Require

repair

or

replacement.

Wire lead open ……….

A

..

Require

repair

or

replacement.

Wire lead shorted …….

A

..

Require

repair

or

replacement.

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

WHEEL ATTACHING HARDWARE

For conditions noted below, also check condition of wheel stud holes.
CAUTION: Proper lug nut torque is essential. Follow manufacturer’s torque specifications and tightening sequence. DO NOT lubricate threads unless specified by the vehicle manufacturer.
WHEEL ATTACHING HARDWARE INSPECTION
Condition Code Procedure
Bent ……………….. A ………… Require replacement. Broken ……………… A …….. (1) Require replacement. Loose ………………. B … Require repair or replacement of affected component.

Lug nut flats rounded …

A

….. Require replacement

of nut.

Lug nut installed

backward ……………

B

…………….. Require

repair.

Lug nut mating surface
dished …………….. A ….. Require replacement of nut. Lug nut mating type

incorrect …………..

B

….. Require replacement of nut.

Lug nut seized ……….

A

…… Require replacement of nut

and/or stud.

Stud incorrect ……….

B

…. Require replacement of stud.

Threads damaged ………

A

… Require repair or replacement

of component with damaged

threads.

Threads stripped (threads

missing) ……………

A

………. Require replacement of

component with stripped

threads.

(1) – Some manufacturers require replacement of all studs on any wheel if two or more studs or nuts on the same wheel are broken or missing.

WHEEL BEARINGS, RACES AND SEALS

NOTE: Grease seal replacement is required if seal is removed.
You are not required to replace these components in axle sets. Determine the need to replace based upon the individual component conditions that follow.
WHEEL BEARINGS, RACES AND SEALS INSPECTION
Condition Code Procedure
Axle seal on drive axle
leaking ……………. A . Require replacement of seal and inspection of axle, bearing, housing, and vent tube.
Bearing end-play exceeds
specifications ……… B .. Require adjustment of bearing, if possible. If proper adjustment cannot be obtained, require replacement of bearing assembly.
Bearing rollers, balls or races are worn, pitted, or feel rough when rotated as

an assembly

…………

B

.. Require replacement of bearing

assembly.

Seal leaking

…………

A

…… (1) Require replacement of

seal and inspection of bearings.

Spindle worn

…………

B

.. Require replacement of spindle

and bearings.

(1) – Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged vent may force fluid past the seal.

WHEEL CYLINDERS

You are not required to replace or rebuild wheel cylinders in axle sets. However, when rebuilding or replacing a wheel cylinder due
to the conditions that follow, you may suggest rebuilding or replacement of the other wheel cylinder (on the same axle) for preventive maintenance, for example, the part is close to the end of its useful life.
Determine the need to rebuild or replace based upon the individual wheel cylinder conditions that follow.
WHEEL CYLINDER INSPECTION
Condition Code Procedure
Attaching hardware bent . B ….. Require replacement of bent parts.
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware corroded, affecting
structural integrity … A . Require replacement of corroded parts.
Attaching hardware
loose ……………… A .. Require repair or replacement. Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bleeder port damaged (if
non-repairable) …….. A ………… Require replacement. Bleeder screw broken off
in wheel cylinder (if non-

repairable) …………

A

…….. (1) Require replacement.

Bleeder screw plugged …

A

……….. (1) Require repair or

replacement of bleeder screw.

Bleeder screw seized ….

A

…….. (2) Require replacement.

Bore corroded (pitted) ..

B

………… Require replacement.

Bore grooved …………

A

………… Require replacement.

Bore oversized ……….

B

………… Require replacement.

Dust boot missing …….

C

….. Require replacement of dust

boot.

Dust boot torn ……….

A

. (3) Require replacement of dust

boot.

Leaking ……………..

A

……. (4) Require rebuilding or

replacement.

Piston corroded, affecting

performance …………

B

… Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Piston finish worn off ..

B

… Require replacement of piston

and rebuilding or replacement

of wheel cylinder.

Piston stuck in bore ….

A

…. Require replacement of wheel

cylinder.

Loose ……………….

B

.. Require repair or replacement.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

………… Require replacement.

(1) – Only required if the hydraulic system must be opened.
(2) – Seized is defined as bleeder screw that cannot be removed after a practical attempt at removing. Only required if the hydraulic system must be opened.
(3) – Inspect for conditions related to wheel cylinder.
(4) – Leaking is defined as a drop or more. Dampness is normal.

WIRING HARNESSES

NOTE: Copied from Electrical UIGs. WIRING HARNESS INSPECTION
Condition Code Procedure
Application incorrect … B .. Require repair or replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Insulation damaged,

conductors exposed …..

A

.. Require repair or replacement.

Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Open ……………….. A .. Require repair or replacement. Protective shield
(conduit) melted ……. 2 ……….. (1) Suggest repair or replacement.
Protective shield
(conduit) missing …… 2 .. Suggest repair or replacement. Resistance (voltage drop)
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. Voltage drop out of
specification ………. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

 

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