* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
1988 Jeep Cherokee
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:
a Pledge of Assurance to their Customers and
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 nonprofit organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in October, 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and Standards and agreed to follow the UICS in communicating the results of their inspection to their customers. To put some "teeth" in the program, an accreditation requirement for shops was initiated. The requirements are stringent, and a self-policing method has been incorporated which includes the "mystery shopping" of outlets.
We welcome you to join us as we continue our outreach with your support, both the automotive repair industry and your customers will reap the benefits. Please visit MAP at our Internet site www. motorist.org or contact us at:
1444 I Street, NW Suite 700
Washington, DC 20005
Phone (202) 712-9042 Fax (202) 216-9646 January 1999
MAP UNIFORM INSPECTION GENERAL GUIDELINES
OVERVIEW OF SERVICE REQUIREMENTS 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
 - Part does not meet a design specification (regardless of
performance) Ñ - 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 |
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 |
(1) - Determine cause and correct prior to replacement of part.
(2) - Determine cause and correct prior to repair or replacement
of part.
BULB SOCKETS
BULB SOCKET INSPECTION
Condition Code Procedure Attaching hardware broken ................. A ... Require repair or replacement of hardware. Attaching hardware missing ................ C .......... Require replacement of hardware. Attaching hardware not functioning ............ A ... Require repair or replacement of hardware. Broken .................. A .. Require repair or replacement. Bulb seized in socket ... A .. Require repair or replacement. Burned, affecting performance ............ A .............. (1) Require repair or replacement. Burned, not affecting performance ............ 2 .............. (1) Suggest repair or replacement. Connector broken ........ A .. Require repair or replacement. Connector missing ....... C ............ Require replacement. Connector (Weatherpack type) leaking .......... A .. Require repair or replacement. Connector melted ........ A .............. (2) Require repair or replacement. 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. Bleeder screw plugged ... A ........... (1) Require repair or replacement of bleeder screw. Bleeder screw seized .... A ......... (2) Require replacement of caliper. Casting corroded, affecting structural integrity .............. A ............ Require replacement. Casting damaged, affecting structural integrity ... A ............ Require replacement. Dust boot around caliper torn ................... A ..... Require replacement of dust boot. Leaking ................. A .. Require repair or replacement. Mounting pin threads damaged ................ A ... Require repair or replacement of component with damaged threads. 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
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. Contaminated ............ A ........ (2) Require replacement. Inoperative ............. A .............. (3) Require repair or replacement. Leaking externally ...... A .. Require repair or replacement. Leaking internally ...... A .. Require repair or replacement. 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. 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 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. 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.
HYDRO-BOOSTER 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. Does not apply assist, or inadequate assist ...... A .. Require repair or replacement. Leaking ................. B .. Require repair or replacement. Leaks fluid at fitting .. B ........... Require tightening or replacement. Leaks fluid at unit ..... B .. Require repair or replacement. Leaks fluid from pressure hose(s) ................ B . Require replacement of hose(s). Leaks fluid into passenger compartment ............ B .. Require repair or replacement. Threads damaged ......... 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 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.
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