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Volvo 850 checking the drivetrain

 

* DRIVETRAIN SYSTEMS UNIFORM INSPECTION GUIDELINES *

1995 Volvo 850

GENERAL INFORMATION
Drivetrain/Transmission Motorist Assurance Program
Standards For Automotive Repair
All Makes and Models

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

CONTENTS

OVERVIEW OF MOTORIST ASSURANCE PROGRAM
OVERVIEW OF SERVICE REQUIREMENTS & SUGGESTIONS
Drive/Power Train Assemblies
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES TRANSFER CASE ASSEMBLIES
Drive/Power Train Components
ACTUATORS (ELECTRICAL) ACTUATORS (VACUUM) AXLES
BEARINGS AND RACES BELL CRANKS
BELL HOUSINGS BUSHINGS (EXTERNAL) CABLES (SPEEDOMETER)
CABLES (TV, DETENT AND SHIFT) CARRIER BEARINGS
CLUTCH CABLES AND CABLE HOUSINGS CLUTCH DISCS (MANUAL TRANSMISSION) CLUTCH FORKS
CLUTCH LINKAGES (MECHANICAL) CLUTCH MASTER CYLINDERS CLUTCH PEDALS
CLUTCH PIVOTS
CLUTCH PRESSURE PLATES CLUTCH RELEASE BEARINGS
CLUTCH SLAVE CYLINDERS (CONCENTRIC)
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL) COMPANION FLANGES
CONNECTORS
COOLER BYPASS VALVES COOLER LINES
COOLERS
CV JOINTS
DIP STICK TUBES
DIP STICKS (FLUID LEVEL INDICATORS) DOWEL PINS, GUIDES AND PILOT HOLES DRIVE SHAFT FLANGES
DRIVE SHAFTS AND HALF SHAFTS DUST BOOTS
ENGINE MOUNTS EXCITER RINGS FILLER TUBES
FILTERS AND SCREENS
FLANGES
FLEX PLATES
FLUID LEVEL INDICATORS FLUIDS AND LUBRICANTS FLYWHEELS
FORCE MOTORS GUIDES
HALF SHAFTS
HOSES, LINES AND TUBES
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) INTERMEDIATE SHAFT SUPPORT BEARINGS
KEY INTERLOCK SYSTEMS LIMITED SLIPS
LINES
LINKAGES (EXTERNAL) LOCKING HUB ASSEMBLIES LOCKING HUB CONTROL KNOBS LUBRICANTS
METAL-CLAD SEALS METALASTIC JOINTS MODULATOR PINS MODULATORS
MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION) ODOMETER DRIVES (MECHANICAL)
ODOMETER HEADS (MECHANICAL) OIL PANS
PANS
PILOT HOLES PRESSURE PLATES PRESSURE SWITCHES RACES
RUBBER JOINTS (METALASTIC) SCREENS
SEALS
SEALS (METAL-CLAD)
SELECTOR INTERLOCK SYSTEMS SERVOS
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS) SENSORS
SIDE COVERS SLIP YOKES SOLENOIDS
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) SPEEDOMETER-DRIVEN GEAR HOUSINGS SPEEDOMETER/ODOMETER DRIVES (MECHANICAL) SPEEDOMETER/ODOMETER HEADS (MECHANICAL) SPEEDOMETERS AND ODOMETERS (ELECTRONIC) SWITCHES
TONE WHEELS
TOOTHED RINGS (TONE WHEELS) TORQUE CONVERTERS
TRANSAXLE MOUNTS TRANSDUCERS (TRANSMISSION) TRANSMISSION COOLERS TRANSMISSION MOUNTS TRANSMISSION PANS
TRANSMISSION RANGE INDICATORS (PRNDL) TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE) VACUUM CONTROLS
VACUUM HOSES VACUUM MOTORS
VACUUM-OPERATED SWITCHES
VEHICLE SPEED SENSORS VENTS
VIBRATION DAMPERS
WHEEL ATTACHMENT HARDWARE WHEEL SPEED SENSORS
WIRING HARNESSES AND CONNECTORS YOKES AND SLIP YOKES

INTRODUCTION TO MOTORIST ASSURANCE PROGRAM (MAP)

OVERVIEW OF MOTORIST ASSURANCE PROGRAM

The Motorist Assurance Program is the consumer outreach effort of the Automotive Maintenance and Repair Association, Inc. (AMRA). Participation in the Motorist Assurance Program is drawn from retailers, suppliers, independent repair facilities, vehicle manufacturers and industry associations.
Our organization’s mission is to strengthen the relationship between the consumer and the auto repair industry. We produce materials that give motorists the information and encouragement to take greater responsibility for their vehicles-through proper, manufacturer-recommended, maintenance. We encourage participating service and repair shops (including franchisees and dealers) to adopt (1) a Pledge of Assurance to their Customers and (2) the Motorist Assurance Program Standards of Service. All participating service
providers have agreed to subscribe to this Pledge and to adhere to the promulgated Standards of Service demonstrating to their customers that they are serious about customer satisfaction.
These Standards of Service require that an inspection of the vehicle’s (problem) system be made and the results communicated to the customer according to industry standards. Given that the industry did not have such standards, the Motorist Assurance Program successfully promulgated industry inspection communication standards in 1994-95 for the following systems: Exhaust, Brakes, ABS, Steering and Suspension, Engine Maintenance and Performance, HVAC, and Electrical Systems. Further, revisions to all of these inspection were recently published. Further, revisions to all of these inspection communication standards are continually republished. In addition to these, standards for Drive Train and Transmissions have recently been promulgated. Participating shops utilize these Uniform Inspection & Communication Standards as part of the inspection process and for communicating their findings to their customers.
The Motorist Assurance Program continues to work cooperatively and proactively with government agencies and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both regulators and industry. We maintain the belief that industry must retain control over how we conduct our business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and other government officials (and their representatives), concerned with auto repair and/or consumer protection, are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as needed.
To assure auto repair customers recourse if they were not satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other 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 & 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.

DRIVE/POWER TRAIN ASSEMBLIES

SERVICE PROCEDURES REQUIRED AND SUGGESTED FOR PROPER

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

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION
Condition Code Procedure
Any internal component failure that requires removal of the assembly from the vehicle for
service. (1) ……….. A ……….. (2) Require repair or replacement of the automatic transmission/transaxle assembly.
(1) – It is Required that the torque converter and all other failure related components be inspected for cause and condition.
(2) – For components not requiring removal of the assembly, refer to the component listing in this document.

DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES NOTE: Does not include half shafts. DIFFERENTIAL AND FINAL DRIVE ASSEMBLY INSPECTION

Condition Code Procedure
Any internal component failure that requires removal of the assembly from the vehicle for
service. (1) ……….. A … Require repair or replacement of the differential assembly.
(1) – For components not requiring removal of the assembly, refer to the component listing in this document.

MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES

MANUAL TRANSMISSION/TRANSAXLE ASSEMBLY INSPECTION
Condition Code Procedure
Any internal component failure that requires removal of the assembly from the vehicle for
service. (1) ……….. A … Require repair or replacement of the manual transmission/transaxle assembly.
(1) – For components not requiring removal of the assembly,
refer to the component listing in this document.

TRANSFER CASE ASSEMBLIES

TRANSFER CASE ASSEMBLY INSPECTION
Condition Code Procedure
Any internal component failure that requires removal of the assembly from the vehicle for
service. (1) ……….. A … Require repair or replacement of the transfer case differential assembly.
(1) – For components not requiring removal of the assembly, refer to the component listing in this document.

DRIVE TRAIN/COMPONENTS

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)

ACTUATOR (ELECTRICAL) INSPECTION
Attaching hardware
Attaching hardware not
Connector melted,
affecting performance .. A ……….. (1) Require repair or replacement.
Connector melted, not
affecting performance .. 2 ……….. (1) Suggest repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A …….. (2) Require replacement. 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 ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 1 ……….. (1) Suggest repair or
Terminal corroded,
replacement.
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.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of OEM specification.

ACTUATORS (VACUUM)

ACTUATOR (VACUUM) 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,
affecting performance .. A ……….. (1) Require repair or replacement.
Connector melted, not
affecting performance .. 2 ……….. (1) Suggest repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A …….. (2) Require replacement. 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

………..

(1) Require repair or

replacement.

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

AXLES

Worn, affecting

BEARINGS AND RACES

NOTE: When replacing or repacking 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.
BEARING AND RACE INSPECTION
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.
Bearing rollers, balls or races are worn, pitted, or
feel rough when rotated as
an assembly ………… B .. Require replacement of bearing assembly.

BELL CRANKS

BELL CRANK 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.

Bent ………………..

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

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

BUSHINGS (EXTERNAL)

BUSHING (EXTERNAL) INSPECTION
Condition Code Procedure
Attaching hardware
bent ………………. B … Require repair or replacement of bent part if available; otherwise, replace bushing.
Attaching hardware
broken …………….. A … Require replacement of broken part if available; otherwise, replace bushing.
Attaching hardware corroded, affecting
structural integrity … A . Require replacement of corroded part if available; otherwise, replace bushing.
Attaching hardware
incorrect ………….. A ………. Require 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 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 replacement of part with stripped 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 ……………..

A

………… Require replacement.

Noisy ……………….

2

………. (1) Further inspection

required.

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.
(1) – If noise isolated to bushing, suggest repair or replacement.
CAUTION: Use only approved lubricant on rubber bushings.
Petroleum-based lubricants may damage rubber bushings.

CABLES (SPEEDOMETER)

CABLE (SPEEDOMETER) 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.
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 .. .. …….. No service suggested or
Bracket broken, affecting
required.
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket 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 ……………..

A

.. Require repair or

replacement.

Disconnected …………

A

.. Require repair or

replacement.

Kinked ………………

A

.. Require repair or

replacement.

Melted ………………

A

……….. (1) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Routed incorrectly ……

2

…………….. Suggest repair.

Seized ………………

A

.. Require repair or replacement.

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

CABLES (TV, DETENT AND SHIFT)

CABLE (TV, DETENT AND SHIFT) 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.
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 .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement.
Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket 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 ……………..

A

.. Require repair or replacement.

Disconnected …………

A

.. Require repair or replacement.

Frayed ………………

A

………… Require replacement.

Kinked ………………

A

.. Require repair or replacement.

Melted ………………

A

……….. (1) Require repair or

replacement.

Missing ……………..

C

………… Require replacement.

Noisy ……………….

2

.. Suggest repair or replacement.

Out of adjustment …….

B

……….. (2) Require repair or

replacement.

Routed incorrectly ……

2

…………….. Suggest repair.

Seized ………………

A

.. Require repair or replacement.

Self-adjuster

inoperative …………

A

.. Require repair or replacement

of self-adjuster.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

………… Require replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Cable replacement is required if it cannot be adjusted within specifications.

CARRIER BEARINGS

See INTERMEDIATE SHAFT SUPPORT BEARINGS.

CLUTCH CABLES AND CABLE HOUSINGS

CLUTCH CABLE AND CABLE HOUSING INSPECTION
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 TRANSMISSION)

CLUTCH DISC (MANUAL TRANSMISSION) INSPECTION
Condition Code Procedure

Backing plate cracked …

A

…………

Require replacement.

Broken ………………

A

…………

Require replacement.

Contaminated with oil …

A

…………

Require replacement.

Damper cushion broken …

A

…………

Require replacement.

Damper cushion

collapsed ………….. A ………… Require replacement.

Damper spring collapsed .

A

…………

Require replacement.

Damper spring missing ..

C

…….. (1)

Require replacement.

Friction material cracked

through …………….

B

…………

Require replacement.

Friction material flaking
or chunking ………… B ………… Require replacement. Friction material surface
cracking …………… B ……… 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 ……………… A ………… Require replacement. Wear exceeds
specifications (where
applicable) ………… B ………… Require replacement. Worn close to the end of
its useful life …….. 1 ………… Suggest replacement. Worn, affecting
performance ………… A ………… Require replacement.
(1) – Not all clutch discs have springs in all spring chambers on the disc.

CLUTCH FORKS

Worn, affecting

CLUTCH LINKAGES (MECHANICAL)

See LINKAGES (EXTERNAL).

CLUTCH MASTER CYLINDERS

CLUTCH MASTER CYLINDER INSPECTION
Condition Code Procedure

Cover gasket

distorted ..

A

….

Require replacement of cover

gasket.

Cover gasket

gummy ……

A

….

Require replacement of cover

gasket.

Cylinder leaking fluid
from rear of bore …… A .. Require repair or replacement. Cylinder leaking fluid
internally …………. A ………… Require replacement. Dust boot missing ……. C ….. Require replacement of dust boot.
Dust boot punctured ….. A ….. Require replacement of dust boot.
Dust boot torn ………. A ….. Require replacement of dust boot.
Fluid level incorrect … B . Require fluid level adjustment. Housing damaged, affecting
performance ………… A .. Require repair or replacement. Master cylinder has
residue in reservoir
(make parallel w/brakes

when they are done) ….

2

………. (1) Further inspection

required.

Threads damaged ………

A

…… Require repair replacement

Threads stripped (threads

missing) ……………

A

………… Require replacement.

(1) – DO NOT replace master cylinder unless it exhibits conditions listed for replacement. You may suggest fluid change according to OEM service intervals.

CLUTCH PEDALS

CLUTCH PEDAL INSPECTION
Condition Code Procedure
Bent, affecting
performance ………… A .. Require repair or replacement. Broken ……………… A .. Require repair or replacement. Pedal pad missing ……. C ………. Require replacement of pedal pad.
Pivot bushings worn,
affecting performance .. A …. Require replacement of pivot bushings.

CLUTCH PIVOTS

CLUTCH PIVOT INSPECTION
Condition Code Procedure

Bent ………………..

A

………… Require

replacement.

Broken ………………

A

.. Require repair or

replacement.

Cracked ……………..

A

.. Require repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Worn close to the end of
its useful life …….. 1 ………… Suggest replacement. Worn, affecting
performance ………… A ………… Require replacement.

CLUTCH PRESSURE PLATES

See PRESSURE PLATES.

CLUTCH RELEASE BEARINGS

CLUTCH RELEASE BEARING INSPECTION
Condition Code Procedure

Collar broken ………..

A

…………

Require

replacement.

Cracked ……………..

A

…………

Require

replacement.

Rough when rotated as an

assembly ……………

B

…………

Require

replacement.

Seized ………………

A

…………

Require

replacement.

Wear exceeds
specifications ……… B ………… Require replacement. Worn close to the end of
its useful life …….. 1 ………… Suggest replacement. Worn, affecting
performance ………… A ………… Require replacement.

CLUTCH SLAVE CYLINDERS (CONCENTRIC)

CLUTCH SLAVE CYLINDER (CONCENTRIC) INSPECTION
Carrier assembly worn,
Worn, affecting

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

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

Binding ……………..

A

.. Require repair or replacement.

Bleeder port damaged (not

repairable) …………

A

…….. (1) Require replacement.

Bleeder port damaged
(repairable) ……….. A …………. (1) Require repair. Bleeder screw broken off

in slave cylinder ……

A

…….. (1) Require replacement.

Bleeder screw seized ….

A

…….. (2) Require replacement.

Bore corroded (pitted) ..

B

………… Require replacement.

Bore grooved …………

A

………… Require replacement.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

………… Require replacement.

(1) – Only required if the hydraulic system must be opened. (2) – Seized is defined as a bleeder screw that cannot be
removed after a practical attempt at removing it has been made.

COMPANION FLANGES

See YOKES AND SLIP YOKES.

CONNECTORS

See WIRING HARNESSES AND CONNECTORS.

COOLER BYPASS VALVES

COOLER BYPASS VALVE INSPECTION
Condition Code Procedure
Inoperative …………. A ………… Require replacement. Installed incorrectly … A …………….. Require repair. Leaking …………….. A .. Require repair or replacement. Restricted ………….. A .. Require repair or replacement.

COOLER LINES

COOLER LINE INSPECTION
Condition Code Procedure
Abrasion damage, affecting
structural integrity … A .. Require repair or replacement. Abrasion damage, not
affecting structural
integrity ………….. .. …….. No service suggested or required.
Application incorrect … B ………… Require replacement. Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Clamp corroded, not
reusable …………… 1 ………… Suggest replacement. Connected incorrectly … A …………….. Require repair. Corroded, affecting
structural integrity … A ………… Require replacement. Corroded, not affecting
structural integrity … .. …….. No service suggested or required.
Cracked …………….. A .. Require repair or replacement. Fitting type incorrect
Protective sleeves
damaged ……………. 2 . Suggest replacement of sleeves. Protective sleeves
missing ……………. C . Require replacement of sleeves. Restricted, affecting

performance …………

A

.. Require repair or replacement.

Routed incorrectly ……

2

…………….. Require repair.

Swollen ……………..

1

………… Suggest

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

Type incorrect ……….

1

.. Suggest repair or

replacement.

COOLERS

See TRANSMISSION COOLERS.

CV JOINTS

CV JOINT INSPECTION
Condition Code Procedure
Bearing, bushing or seal surface worn, affecting
performance ………… A .. Require repair or replacement. Boot clamp broken ……. A … Require repair or replacement of 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. 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 ……….. (1) Require repair or replacement of CV joint.
Housing worn to the extent that it no longer performs

its intended function ..

A

……….. (1) Require repair or

replacement of CV joint.

Holes elongated ………

A

………… Require replacement.

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.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

………… Require replacement.

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

DIP STICK TUBES

Hold down bracket

DIP STICKS (FLUID LEVEL INDICATORS)

DIP STICK (FLUID LEVEL INDICATOR) INSPECTION
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

DOWEL PIN, GUIDE AND PILOT HOLE INSPECTION
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.

DRIVE SHAFT FLANGES

See COMPANION FLANGES.

DRIVE SHAFTS AND HALF SHAFTS

DRIVE SHAFT AND HALF SHAFT INSPECTION
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 replacement.

Splines worn close to

the end of their

useful life …………

1

………… Suggest

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.

DUST BOOTS

NOTE: Does not include CV boots. DUST BOOT INSPECTION
Condition Code Procedure
Cracked, not leaking …. 1 ………… Suggest replacement. Missing …………….. C ………… Require replacement. Leaking …………….. A .. Require repair or replacement.
Torn ……………….. A ………… Require replacement.

ENGINE MOUNTS

See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION).

EXCITER RINGS

See TOOTHED RINGS (TONE WHEELS).

FILLER TUBES

See DIP STICK TUBES.

FILTERS AND SCREENS

FILTER AND SCREEN INSPECTION
Condition Code Procedure

At service interval …..

3

………… Suggest replacement.

Bent ………………..

A

.. Require repair or replacement.

Exceeding service

interval ……………

3

…………

Suggest replacement.

Missing ……………..

C

…………

Require replacement.

Near service interval …

3

…………

Suggest replacement.

Restricted …………..

A

………..

(1) Require repair or

replacement.

Torn ………………..

A

…………

Require replacement.

Worn, affecting performance (metal or
nylon screen type) ….. A .. Require repair or replacement.
(1) – Further inspection may be required to determine the source of restriction or contamination.

FLANGES

See COMPANION FLANGES.

FLEX PLATES

FLEX PLATE INSPECTION
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 …………….. A ………… 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 replacement.

FLUID LEVEL INDICATORS

See DIP STICKS (FLUID LEVEL INDICATORS).

FLUIDS AND LUBRICANTS

FLUID AND LUBRICANT INSPECTION
Condition Code Procedure
Application incorrect … B …….. (1) Require replacement. At service interval ….. 3 ………… Suggest replacement. Beyond service interval . 3 ………… Suggest replacement. Burned ……………… .. ……… (2) Further inspection required.
Contaminated, for example, fluid other than hydraulic
fluid present ………. A or B …. (3)(4) Require service. Exceeding service
interval …………… 3 ………… Suggest replacement. Hydraulic fluid
incorrect ………….. B ………… (5) Require service. Level incorrect ……… B ….. Require correction of fluid level.
Near service interval … 3 ………… Suggest replacement. Rubber master cylinder
cover gasket distorted
and gummy ………….. A ………… (3) Require service. Varnished …………… .. ……… (6) Further inspection required.
(1) – Determine and correct cause.
(2) – Fluid that is burned indicates a serious problem.
Determine and correct the cause.
(3) – If a fluid other than hydraulic fluid is present in the hydraulic system which DOES affect the rubber parts, the required service is to: 1) remove all components having rubber parts from the system, 2) flush lines with denatured alcohol or hydraulic cleaner, 3) repair or replace all components having rubber parts, and 4) bleed and flush with correct hydraulic fluid. (Code A)
(4) – If a fluid other than hydraulic fluid is present in the hydraulic system which DOES NOT affect the rubber parts, the required service is to flush and fill with the correct hydraulic fluid. (Code B)
(5) – If a fluid other than specification hydraulic fluid is present in the hydraulic system, the required service is to flush and fill with the correct hydraulic fluid.
(6) – Fluid that is varnished may indicate a serious problem.
Determine and correct the cause.

FLYWHEELS

NOTE: Clutch disc replacement does not necessitate flywheel reconditioning, unless other conditions justify the reason to do so.
FLYWHEEL INSPECTION
Condition
Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Cracked (other than
mounting area) ……… A …… (1) Require resurfacing or replacement.
Cracks in mounting area . B ………… Require replacement. Hard spots ………….. B .. Require repair or replacement. Ring gear broken …….. A ….. Require replacement of ring gear.
Ring gear teeth worn,
affecting performance .. A ….. Require replacement of ring gear.
Runout exceeds
specifications ……… B .. Require repair or replacement. Scored ……………… B .. Require repair or replacement. Surface cracks after
resurfacing to manufacturer’s minimum
specifications ……… B ………… Require replacement. Wear exceeds
specifications ……… B ………… Require replacement. Worn close to the end of
its useful life …….. 1 ………… Suggest replacement. Worn, affecting

performance …………

A

.. Require repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

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

FORCE MOTORS

See ACTUATORS (ELECTRICAL).

GUIDES

See DOWEL PINS, GUIDES AND PILOT HOLES.

HALF SHAFTS

See DRIVE SHAFTS AND HALF SHAFTS.

HOSES, LINES AND TUBES

HOSE, LINE AND TUBE INSPECTION
Condition Code Procedure

Application incorrect …

B

………… Require replacement.

Connected incorrectly …

A

…………….. Require repair.

Corroded, not reusable ..

1

………… Suggest

replacement.

Cracked ……………..

A

………… Require

replacement.

Dry-rotted …………..

1

.. Suggest repair or

replacement.

Hard ………………..

1

.. Suggest repair or

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. Maintenance intervals … 3 ………… Suggest 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.

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) HOUSING (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY) INSPECTION 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 .. A ……….. (1) 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.
(1) – See DOWEL PINS, GUIDES AND PILOT HOLES.

INTERMEDIATE SHAFT SUPPORT BEARINGS

INTERMEDIATE SHAFT SUPPORT BEARING INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bearing rollers, balls or races are worn, pitted, noisy, or feel rough when
rotated as an assembly . A .. Require replacement of bearing assembly.
Bracket bent, affecting
performance ………… A .. Require repair or replacement. Bracket bent, not
affecting performance .. .. …….. No service suggested or required.
Bracket broken, affecting
performance ………… A ………… Require replacement. Bracket broken, not
affecting performance .. .. …….. No service suggested or required.
Bracket corroded,
affecting performance .. A .. Require repair or replacement. Bracket corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Bracket cracked, affecting
performance ………… A .. Require repair or replacement. Bracket cracked, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket holes elongated,
affecting performance .. A .. Require repair or replacement. Bracket holes elongated,
not affecting
performances) ………. .. …….. No service suggested or required.
Bracket loose, affecting
performance ………… A .. Require repair or replacement. Bracket loose, not
affecting performance .. 1 .. Suggest repair or replacement. Bracket missing ……… C ………… Require replacement. Cracked …………….. .. ……….. Require replacement. Rough (brinelling,
spalling) ………….. A ………… Require replacement. Rubber deteriorated,

affecting performance ..

A

………… Require

replacement.

Seized ………………

A

………… Require

replacement.

KEY INTERLOCK SYSTEMS

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

LIMITED SLIPS

See DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES.

LINES

See HOSES, LINES AND TUBES.

LINKAGES (EXTERNAL)

LINKAGE (EXTERNAL) INSPECTION
Condition Code Procedure
Components missing …… C .. Require replacement of missing components.
Linkage bent, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage bent, not
affecting performance .. 2 … Suggest repair or replacement of linkage.
Linkage binding, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage binding, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage broken ………. A … Require repair or replacement of linkage.
Linkage loose, affecting
performance ………… A … Require repair or replacement of linkage.
Linkage loose, not
affecting performance .. 1 … Suggest repair or replacement of linkage.
Linkage missing ……… C ………… Require replacement.

Linkage noisy ………..

2

..

Suggest

repair

or

replacement.

Out of adjustment …….

B

..

Require

repair

or

replacement.

Worn to the extent that it

no longer performs its

intended function ……

A

..

Require

repair

or

replacement.

LOCKING HUB ASSEMBLIES

LOCKING HUB ASSEMBLY INSPECTION
Condition Code Procedure

Inoperative ………….

A

………..

(1) Require repair or

replacement.

Loose ……………….

A

.. Require

repair or replacement.

Seized in any position ..

A

.. Require

repair or replacement.

(1) – Inoperative includes intermittent operation.

LOCKING HUB CONTROL KNOBS

LOCKING HUB CONTROL KNOB INSPECTION
Condition Code Procedure
Damaged, affecting
performance ………… A ………… Require replacement. Missing …………….. C ………… Require replacement. Worn, affecting
performance ………… A ………… Require replacement.

LUBRICANTS

See FLUIDS AND LUBRICANTS.

METAL-CLAD SEALS

See SEALS.

METALASTIC JOINTS

See RUBBER JOINTS (METALASTIC).

MODULATOR PINS

MODULATOR PIN INSPECTION
Condition Code Procedure
Application incorrect … B ………… Require replacement. Missing …………….. C ………… Require replacement.

MODULATORS

MODULATOR INSPECTION
Condition Code Procedure
Bent, affecting
performance ………… A ………… Require replacement. Contaminated (water, fuel,
etc.) ……………… A …….. (1) Require replacement.

Housing cracked ………

A

………… Require replacement.

Inoperative ………….

A

…….. (2) Require replacement.

Leaking fluid

externally ………….

A

.. Require repair or replacement.

Leaking fluid

internally ………….

A

………… Require

replacement.

Leaking vacuum ……….

A

………… Require

replacement.

Nipple broken ………..

A

………… Require

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

(1) – Further inspection is required to determine the cause of the contamination.
(2) – Inoperative includes intermittent operation or out of OEM
specification.

MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION)

MOUNT (ENGINE, TRANSAXLE AND TRANSMISSION) INSPECTION
Attaching hardware
Attaching hardware not
Mounting hole worn,
affecting performance .. A ………… Require replacement. Mounting hole worn, not
affecting performance .. .. …….. No service suggested or required.
Rubber deteriorated,
affecting performance .. A ………… Require replacement. Rubber deteriorated, not
affecting performance .. .. …….. No service suggested or required.
Threads damaged ……… A .. Require repair or replacement. Threads stripped (threads
missing) …………… A ………… Require replacement.

ODOMETER DRIVES (MECHANICAL)

See SPEEDOMETER/ODOMETER DRIVES (MECHANICAL).

ODOMETER HEADS (MECHANICAL)

See SPEEDOMETER/ODOMETER HEADS (MECHANICAL).

OIL PANS

See TRANSMISSION PANS.

PANS

See TRANSMISSION PANS.

PILOT HOLES

See DOWEL PINS, GUIDES AND PILOT HOLES.

PRESSURE PLATES

PRESSURE PLATE INSPECTION
Condition Code Procedure
Balance weight missing .. C ………… Require replacement. Broken ……………… A ………… Require replacement. Contact surface
distorted ………….. B ………… Require replacement. Cracks ……………… B ………… Require replacement. Fingers bent ………… A ………… Require replacement. Hard spots ………….. B ………… Require replacement.

Scored ………………

B

…………

Require

replacement.

Spring rate less than

specifications ………

B

…………

Require

replacement.

Worn, affecting
performance ………… A ………… Require replacement. Worn beyond
specifications ……… B ………… Require replacement. Worn close to the end of
its useful life …….. 1 ………… Suggest replacement.

PRESSURE SWITCHES

See SWITCHES.

RACES

See BEARINGS AND RACES.

RUBBER JOINTS (METALASTIC)

These joints may be found on half and/or drive shafts. They are usually found on European vehicles featuring a three-lug drive flange. They may be equipped with a centering ball or pin.
RUBBER JOINT (METALASTIC) INSPECTION
Condition Code Procedure
Drive flange bent ……. A …………. Require repair or replacement.
Drive flange damaged,
affecting performance .. A ………… Require replacement. Rubber drive joint
cracked ……………. 2 ………… Suggest replacement. Rubber drive joint
damaged, affecting
performance ………… A ………… Require replacement. Rubber drive joint split
between mounting holes . A ………… Require replacement. Rubber drive joint torn at
mounting holes ……… A ………… Require replacement. Rubber drive joint weather-
cracked ……………. .. …….. No service suggested or required.

SCREENS

See FILTERS AND SCREENS.

SEALS

SEAL INSPECTION
Condition Code Procedure
Leaking …………….. A ……….. (1) Require repair or replacement.
(1) – Require inspection of mating and sealing surface and repair or replace as necessary. Check vent. A plugged
vent may force fluid past the seal.

SEALS (METAL-CLAD)

See SEALS.

SELECTOR INTERLOCK SYSTEMS

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

SERVOS

See ACTUATORS (VACUUM).

SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK SYSTEMS)

See:
ACTUATORS (ELECTRICAL) CABLES
LINKAGES (EXTERNAL) SWITCHES

SENSORS

SENSOR INSPECTION
Condition
Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack
type) leaking ………. A .. Require repair or replacement. Connector melted …….. A ……….. (1) Require repair or replacement.
Connector missing ……. C ………… Require replacement. Inoperative …………. A ……….. (2) Require repair or replacement.
Leaking
(vacuum/fluid/air) ….. A ………… Require replacement. Out of adjustment ……. B ………. (3) Further inspection required.
Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not

affecting performance ..

1

.. Suggest repair or

replacement.

Threads damaged ………

A

.. Require repair or

replacement.

Threads stripped (threads

missing) ……………

A

………… Require

replacement.

(1) – Determine cause and correct prior to repair or replacement of part.
(2) – Inoperative includes intermittent operation or out of specification.
(3) – Follow OEM recommended adjustment procedures. Repair or replace if out of specification.

SIDE COVERS

See TRANSMISSION PANS.

SLIP YOKES

See YOKES AND SLIP YOKES.

SOLENOIDS

See:
ACTUATORS (ELECTRICAL) ACTUATORS (VACUUM)

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

SPEED SENSOR (ELECTRONIC WHEEL AND VEHICLE) INSPECTION
Condition Code 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
replacement.
replacement.

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.

SPEEDOMETER-DRIVEN GEAR HOUSINGS

See SPEEDOMETER/ODOMETER DRIVES (MECHANICAL).

SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)

SPEEDOMETER/ODOMETER DRIVE (MECHANICAL) INSPECTION
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

…….. (1) Require replacement.

Leaking ……………..

A

.. 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.
(1) – Inoperative includes intermittent operation.

SPEEDOMETER/ODOMETER HEADS (MECHANICAL)

SPEEDOMETER/ODOMETER HEAD (MECHANICAL) INSPECTION
Attaching hardware
Attaching hardware not
missing) …………… A ………… Require replacement.
(1) – If lens is available as a separate part, require replacement of lens only.
(2) – Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification, or out of range.

SPEEDOMETERS AND ODOMETERS (ELECTRONIC)

SPEEDOMETER AND ODOMETER (ELECTRONIC) INSPECTION
Attaching hardware
Attaching hardware not
of hardware. Connector broken …….. A .. Require repair or replacement. Connector (Weatherpack

type) leaking ……….

A

.. Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

…………

Require replacement.

Leaking ……………..

A

…………

Require replacement.

Lens broken ………….

A

………..

(2) Require repair or

replacement. Lens cloudy …………. 2 ……….. (2) Suggest repair or replacement.
Lens missing ………… C ……….. (2) Require repair or replacement.
Malfunctioning ………. A ……….. (3) Require repair or replacement.
Mechanical head noisy … 2 .. Suggest repair or replacement. Terminal broken ……… A .. Require repair or replacement. Terminal burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.
(2) – If lens is available as a separate part, require replacement of lens only.
(3) – Includes inoperative, intermittent operation, failure to perform all functions, out of OEM specification,
or out of range.

SWITCHES

SWITCH INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Binding, affecting
performance ………… A .. Require repair or replacement. Binding, not affecting
performance ………… 2 .. Suggest repair or replacement. Broken ……………… A .. Require repair or replacement. Burned, affecting
performance ………… A ……….. (1) Require repair or replacement.
Burned, not affecting
performance ………… 2 ……….. (1) Suggest repair or
Cracked, affecting
replacement.
performance ………… A .. Require repair or replacement. Cracked, not affecting
performance ………… 1 .. Suggest repair or 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.

TONE WHEELS

See TOOTHED RINGS (TONE WHEELS).

TOOTHED RINGS (TONE WHEELS)

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 (TONE WHEEL) 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.

TORQUE CONVERTERS

TORQUE CONVERTER INSPECTION
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 ……………..

A

.. 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

See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION).

TRANSDUCERS (TRANSMISSION)

See SENSORS.

TRANSMISSION COOLERS

TRANSMISSION COOLER INSPECTION

Condition C

ode

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.

TRANSMISSION MOUNTS

See MOUNTS (ENGINE, TRANSAXLE AND TRANSMISSION).

TRANSMISSION PANS

TRANSMISSION PAN INSPECTION
Condition Code Procedure
Bent, interfering with filter or other internal
components …………. A .. Require repair or replacement. Leaking …………….. A .. Require repair or replacement.

TRANSMISSION RANGE INDICATORS (PRNDL)

TRANSMISSION RANGE INDICATOR (PRNDL) INSPECTION

Condition C

Binding ……………..

ode

A

Procedure

.. 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 …….

A

…………….. Require repair.

Worn, affecting

performance ………… A .. Require repair or replacement.

TUBES

See HOSES, LINES AND TUBES.

UNIVERSAL JOINTS (CARDON OR CROSS TYPE)

UNIVERSAL JOINT (CARDON OR CROSS TYPE) INSPECTION
Condition Code Procedure
Attaching hardware
broken …………….. A … Require repair or replacement of hardware.
Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not
functioning ………… A … Require repair or replacement of hardware.
Bearing cap distorted … B ………… Require replacement. Binding …………….. A ………… Require replacement. Cross (trunion) worn,
affecting performance .. A ………… Require replacement. Double cardon centering
ball damaged ……….. A ………… Require replacement. Double cardon centering
ball worn, affecting
performance ………… A ………… Require replacement. Double cardon centering
spring broken ………. A ………… Require replacement. Double cardon centering
spring missing ……… C ………… Require replacement. Double cardon centering
Worn, affecting
performance ………… A ………… Require replacement.
(1) – A broken grease fitting does not require replacement of the U-Joint.
(2) – A missing grease fitting does not require replacement of the U-Joint.

VACUUM CONTROLS

See ACTUATORS (VACUUM).

VACUUM HOSES

See HOSES, LINES AND TUBES.

VACUUM MOTORS

See ACTUATORS (VACUUM).

VACUUM-OPERATED SWITCHES

See SWITCHES.

VEHICLE SPEED SENSORS

See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE).

VENTS

VENT INSPECTION
Condition Code Procedure
Broken ……………… A ………… Require replacement. Missing …………….. C ………… Require replacement. Plugged …………….. A ……….. (1) Require repair or replacement.
(1) – A plugged vent may force fluid past the seal.

VIBRATION DAMPERS

VIBRATION DAMPER INSPECTION
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.
CAUTION: Proper lug nut torque is essential. Follow recommended torque specifications and tightening sequence. DO NOT lubricate threads unless specified by the vehicle manufacturer.
WHEEL ATTACHMENT 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 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

. (2) Require replacement of nut.

Lug nut seized ……….

A

. (2) Require replacement of nut.

Stud incorrect ……….

B

…. Require replacement of stud.

Threads damaged ………

A

.. Require repair or replacement.

Threads stripped (threads

missing) ……………

A

………… Require replacement.

(1) – 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.
(2) – Only required if removing wheel.

WHEEL SPEED SENSORS

See SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE).

WIRING HARNESSES AND CONNECTORS

WIRING HARNESS AND CONNECTOR INSPECTION
Condition Code Procedure

Application incorrect …

B

.. Require repair or replacement.

Attaching hardware

broken ……………..

A

… Require repair or replacement

of hardware.

Attaching hardware
missing ……………. C ………. Require replacement of hardware.
Attaching hardware not

functioning …………

A

..

Require repair or replacement

of hardware.

Connector broken ……..

A

..

Require repair or replacement.

Connector (Weatherpack

type) leaking ……….

A

..

Require repair or replacement.

Connector melted ……..

A

……….. (1) Require repair or

replacement.

Connector missing …….

C

………… Require replacement.

Insulation damaged,

conductors exposed …..

A

.. Require repair or replacement.

Insulation damaged,
conductors not exposed . 1 ………… Suggest replacement. Open ……………….. A .. Require repair or replacement. Protective shield
(conduit) melted ……. 2 ……….. (1) Suggest repair or replacement.
Protective shield
(conduit) missing …… 2 .. Suggest repair or replacement. Resistance (voltage drop)
Terminal burned, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal corroded,
affecting performance .. A .. Require repair or replacement. Terminal corroded, not
affecting performance .. 2 .. Suggest repair or replacement. Terminal loose, affecting
performance ………… B .. Require repair or replacement. Terminal loose, not
affecting performance .. 1 .. Suggest repair or replacement. Transmission connector
leaking ……………. .. ….. See TRANSMISSION ASSEMBLY. Voltage drop out of
specification ………. A .. Require repair or replacement.
(1) – Determine cause and correct prior to repair or replacement of part.

YOKES AND SLIP YOKES

YOKE AND SLIP YOKE INSPECTION
Condition
Code 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, affecting
performance ………… A ………… Require replacement. Splines worn close
to the end of their
useful life ………… 1 ………… Suggest 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.

 

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