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* BRAKE SYSTEM UNIFORM INSPECTION GUIDELINES *
1993 Nissan Sentra

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

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

SHOE HARDWARE SHOES SOCKETS SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE) STEEL BRAKE LINES STOPLIGHT SWITCHES SWITCHES TIRES TOOTHED RINGS (TONE WHEEL) VACUUM BOOSTERS VACUUM HOSES VALVES WHEEL ATTACHING HARDWARE WHEEL BEARINGS, RACES AND SEALS WHEEL CYLINDERS WIRING HARNESSES

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

satisfied with a repair transaction, the Motorist Assurance Program offers mediation and arbitration through MAP/BBB-CARE and other 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 B - Part does not meet a design specification (regardless of performance) C - Part is missing NOTE: When a repair is required, the shop must refuse partial service to the system in question, if the repair creates or continues an unsafe condition. Reasons to Suggest Repair or Replacement 1 - Part is close to the end of its useful life (just above discard specifications, or weak; failure likely to occur soon, etc.) 2 - To address a customer need, convenience, or request (to stiffen ride, enhance performance, eliminate noise, etc.) 3 - To comply with maintenance recommended by the vehicle's Original Equipment Manufacturer (OEM) 4 - Technician's recommendation based on substantial and informed experience NOTE: Suggested services are always optional. When presenting suggested repairs to the customer, you must present the facts, allowing the customer to draw their own conclusions

and make an informed decision about how to proceed.

BRAKES SERVICE PROCEDURES REQUIRED & SUGGESTED FOR PROPER
VEHICLE OPERATION Some states may have specifications that differ from OEM. Check your local/state regulations. Where state or local laws are stricter, they take precedence over these guidelines.

ACCELEROMETERS (G SENSOR OR LATERAL)
ACCELEROMETER INSPECTION Condition

Broken .................. Connector loose ......... Loose ................... Missing ................. Out of position ......... Output signal incorrect .

ACCUMULATOR INSPECTION Condition

Leaking ................. Missing ................. Pre-charge incorrect ....

See BACKING PLATES.

NOTE:

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.

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Code A A B C B B

Procedure

............ Require replacement. .. Require repair or replacement. .. Require repair or replacement. ............ Require replacement. ....... Require re-positioning to vehicle manufacturer's specifications. ............ Require replacement.

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ACCUMULATORS

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Code B C B ............ ............ ............

Procedure

Require replacement. Require replacement. Require replacement.

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ANCHOR PINS ANTI-LOCK BRAKE SYSTEMS
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.

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

Anchor pin bent ......... Anchor pin broken ....... Anchor pin worn, affecting structural integrity ... Backing plate bent ...... Backing plate broken .... Backing plate cracked ... Corroded, affecting structural integrity .... Loose ................... Missing ................. Shoe lands worn .........

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

Beyond service interval

Brake fluid type incorrect .............. Contaminated, for example, fluid other than brake fluid present .......... Hydraulic component ..... overhaul or replacement Rubber master cylinder cover gasket distorted and gummy ..............

(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)

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Code B A B B A B A B C A ............ Require .. Require repair or ............ Require .. Require repair or ............ Require .. Require repair or ............ Require .. Require repair or

Procedure

.. Require repair or replacement. ............ Require replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement.

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BRAKE FLUID

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Code 3 B . .. .. A .......... If a fluid other than brake fluid is present in the brake

Procedure

Suggest flushing and refilling with correct fluid. Require flushing and refilling with correct fluid.

A or B ....... ( 1) Require service. 3 .. Suggest flushing and refilling with correct fluid. ( 2) Require replacement of gasket.

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 PEDAL INSPECTION Condition

Bent, affecting performance ............ Broken .................. Pedal pad missing ....... Pedal pad worn .......... Pivot bushings worn, affecting performance ..

BRAKE SHOE HARDWARE INSPECTION Condition

Broken .................. Distorted ............... Missing ................. Surfaces rust-pitted .... Worn, affecting performance ............

BRAKE STOPLIGHT INSPECTION Condition

Bent .................... Broken .................. Connector broken ........ Connector (Weatherpack type) leaking ..........

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BRAKE FRICTION MATERIAL
See FRICTION MATERIAL.

BRAKE PADS
See FRICTION MATERIAL.

BRAKE PEDALS

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Code A A C 1 A ....

Procedure

.. Require repair or replacement. .. Require repair or replacement. .... Require replacement of pedal pad. ............ Suggest replacement. Require replacement of pivot bushings.

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BRAKE SHOES
See FRICTION MATERIAL.

BRAKE SHOE HARDWARE
See also SELF-ADJUSTING SYSTEMS.

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Code A A C 1 A ............ ............ ............ ............ ............ Require Require Require Suggest

Procedure

replacement. replacement. replacement. replacement.

Require replacement.

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BRAKE STOPLIGHT SWITCHES

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Code B A A A ..

Procedure

............ Require replacement. ............ Require replacement. .. Require repair or replacement. Require repair or replacement.

Connector melted ........ Connector missing ....... Missing ................. Out of adjustment ....... Output signal incorrect . Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance ... Terminal corroded, not affecting performance ... Terminal loose, affecting performance ............ Terminal loose, not affecting performance ... Threads damaged ......... Threads stripped (threads missing) ...............

A C C B B A 2 A 2 B 1 A A

........ ( 1) Require replacement. ............ Require replacement. ............ Require replacement. ........... Require adjustment or replacement. ............ Require replacement. .............. .. .. .. .. .. .. ( 2) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Require replacement.

............

(1) - Determine cause and correct prior to replacement of part. (2) - Determine cause and correct prior to repair or replacement of part.

BULB SOCKET INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Broken .................. Bulb seized in socket ... Burned, affecting performance ............ Burned, not affecting performance ............ Connector broken ........ Connector missing ....... Connector (Weatherpack type) leaking .......... Connector melted ........ Corroded, affecting performance ............ Corroded, not affecting performance ............ Leaking ................. Melted ..................

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BULB SOCKETS

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Code A C A A A A 2 A C A A A 2 A A ... .......... ... .. .. .............. .............. ..

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require repair or replacement. Require repair or replacement. ( 1) Require repair or replacement.

( 1) Suggest repair or replacement. .. Require repair or replacement. ............ Require replacement. .. Require repair or replacement. .............. ( 2) Require repair or replacement. Require repair or replacement.

.. Suggest repair or replacement. .. Require repair or replacement. ........ ( 2) Require replacement.

Shorted ................. Terminal broken ......... Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance ..

A A A 2 A 2 B 1

.. ..

Require repair or replacement. Require repair or replacement. ( 2) Require repair or replacement.

.............. .. .. .. .. ..

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. 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.

NOTE:

BULB AND LED INSPECTION Condition

Application incorrect ... Base burned, affecting performance ............ Base burned, not affecting performance ............ Base corroded, affecting performance ............ Base corroded, not affecting performance .. Base loose, affecting performance ............ Base loose, not affecting performance ............ Burned out .............. Intermittent ............ Missing ................. Seized in socket ........ Terminal broken ......... Terminal burned, affecting performance ............ Terminal burned, not affecting performance ..

Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............

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BULBS AND LEDS
Copied from Electrical UIGs and modified. Does not include soldered-in components.

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Code B A 2 A 2 B 1 A A C A A A 2 A 2 B ........ .............. .............. .. .. .. .. Suggest repair or ............ Require ............ Require ............ Require .. Require repair or .. Require repair or .............. .............. .. .. ..

Procedure

( 1) Require replacement. ( 2) Require repair or replacement. ( 2) Suggest repair or replacement.

Require repair or replacement. Suggest repair or replacement. Require repair or replacement. replacement. replacement. replacement. replacement. replacement. replacement.

( 2) Require repair or replacement. ( 2) Suggest repair or replacement.

Require repair or replacement. Suggest repair or replacement. 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 INSPECTION Condition

Bent ................... Broken .................. Corroded, affecting performance ............ Dust boots on slider pin (bolt) missing ......... Dust boots on slider pin (bolt) torn ............ Missing ................. Shim bent ............... Shim (OE standard) missing ................ Shim out of position .... Shim worn ............... ..

Slider pin (bolt) bent

Slider pin (bolt) rust-pitted ............ Slider pin (bolt) worn ..

Threads damaged ......... Threads stripped (threads missing) ............... Worn, affecting performance ............

(1) - Removal is acceptable if shim is not OE. (2) - Aftermarket shims may be suggested to reduce noise.

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.

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CALIPER HARDWARE

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Code A A A C A C A C B A B A A A A A .. .. .. ... ... ............ ............

Procedure

Require repair or replacement. Require repair or replacement. Require repair or replacement. Require replacement of boots.

... Require replacement of boots. ............ Require replacement. ............. ( 1) Require removal or replacement. ........ ( 2) Require replacement. ............. ( 1) Require removal or replacement. ............. ( 1) Require removal or replacement. ... Require replacement of slider pin or bolt and lubricants. Require replacement of slider pin or bolt and lubricants. ... Require replacement of slider pin or bolt and lubricants. .. Require repair or replacement. Require replacement. Require replacement.

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CALIPERS

CALIPER INSPECTION Condition

Bleeder port damaged

Bleeder screw broken off in caliper ............. Bleeder screw plugged Bleeder screw seized ... ....

Casting corroded, affecting structural integrity .............. Casting damaged, affecting structural integrity ... Dust boot around caliper torn ................... Leaking ................. Mounting pin threads damaged ................ Mounting pin threads stripped in caliper bracket (threads missing) ............... Mounting pin threads stripped in steering knuckle (threads missing) ............... Mounting pin threads stripped (threads missing) ............... Parking brake cable support, lever, or return spring bent ............ Parking brake cable support, lever, or return spring broken .......... Parking brake mechanism in caliper inoperative .... Piston corroded (pitted or peeling chrome plating) ............... Piston damaged, affecting performance ............ Piston damaged, not affecting performance Piston finish worn off

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Code A A A A .... ... ........... A A A A A ............ ............ ..... .. ... A ... A ... A ... A A A B ... ... .. ... B ... .. .. .. B ........ ...

Procedure

Require repair or replacement of caliper.

( 1) Require repair or replacement of caliper. ........... ( 1) Require repair or replacement of bleeder screw. ......... ( 2) Require replacement of caliper. Require replacement. Require replacement.

Require replacement of dust boot. Require repair or replacement. Require repair or replacement of component with damaged threads.

Require repair or replacement of caliper bracket.

Require repair or replacement of steering knuckle. Require repair or replacement of component with stripped threads. Require replacement of parts. Require replacement of parts. Require repair or replacement. Require replacement of piston and rebuilding or replacement of caliper. Require replacement of piston and rebuilding or replacement of caliper. No service suggested or required. Require replacement of piston and rebuilding or replacement

Piston sticking

.........

A A

........... ...

Slide mechanism sticking ...............

of caliper. Require rebuilding or replacement of caliper.

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.

DIGITAL RATIO AXLE CONTROLLER AND BUFFER INSPECTION Condition

Connector broken ........ Connector (Weatherpack type) leaking .......... Connector melted ........ Connector missing ....... Missing ................. Output signal incorrect . Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance ..

(1) - Determine cause and correct prior to replacement of part. (2) - Determine cause and correct prior to repair or replacement of part.

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

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CONTROLLERS
See ELECTRONIC CONTROLLERS.

DIGITAL RATIO AXLE CONTROLLERS AND BUFFERS (DRAC AND DRAB)

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Code A A A C C B A 2 A 2 B 1 .. .. Require repair or ........ ( 1) Require ............ Require ............ Require .. Require repair or .............. .. .. .. .. ..

Procedure

Require repair or replacement. replacement. replacement. replacement. replacement. replacement.

( 2) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement.

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DISABLE SWITCHES
See SWITCHES.

DRUMS

same axle to eliminate uneven braking behavior. Always wash drums after servicing or before installing. DRUM INSPECTION Condition

Balance weight missing

Bell-mouthed, affecting performance ............ Cooling fin broken ......

Cracked ................. Drum diameter is greater than OEM "machine to" specifications but less than "discard at" specifications, and the drum does not require reconditioning ......... Drum diameter will exceed OEM "machine to" specifications after required reconditioning ......... Hard-spotted ............ Measured diameter is greater than OEM discard specifications ......... Out-of-round (runout), affecting performance .. Out-of-round (runout), exceeding manufacturer's specifications ......... Scored ..................

Surface threaded due to improper machining ..... Tapered, affecting performance ............

(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.

Copied fuel pump conditions from engine UIGs & deleted pulsator from leaking conditions. ELECTRICAL PUMP AND MOTOR INSPECTION

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Code .. A .. ........ ....... 1 ........ B 2 B A ............ ....... B B B A ....... ....... ....... .......

Procedure

No service suggested or required.

Require reconditioning or replacement. .. ........ No service suggested or required. B ............ Require replacement.

( 1) Suggest replacement.

........ ( 2) Require replacement. ....... Suggest reconditioning or replacement. Require replacement.

Require reconditioning or replacement. Require reconditioning or replacement. Require reconditioning or replacement. Require reconditioning or replacement. Require reconditioning or replacement.

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ELECTRICAL PUMPS AND MOTORS

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Condition Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Connector broken ........ Connector (Weatherpack type) leaking .......... Connector melted ........ Connector missing ....... Contaminated ............ Inoperative ............. Leaking externally ...... Leaking internally ...... Noisy ................... Terminal broken ......... Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance .. Threads damaged ......... Threads stripped (threads missing) ............... Wire lead conductors exposed ................ Wire lead corroded ...... Wire lead open .......... Wire lead shorted .......

Code A C A A A A C A A A A 2 A A 2 A 2 B 1 A A B A A A ...

Procedure Require repair or replacement of hardware. Require replacement of hardware.

.......... ... ..

Require repair or replacement of hardware. Require repair or replacement.

.. Require repair or replacement. .............. ( 1) Require repair or replacement. ............ Require replacement. ........ ( 2) Require replacement. .............. ( 3) Require repair or replacement. .. Require repair or replacement. .. Require repair or replacement. .. Suggest repair or replacement. .. Require repair or replacement. .............. .. .. .. .. .. .. ( 1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Require replacement. repair repair repair repair or or or or replacement. replacement. replacement. replacement.

............ .. .. .. .. Require Require Require Require

(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 CONTROLLER INSPECTION Condition

Application incorrect ... Attaching hardware missing ................

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ELECTRONIC CONTROLLERS

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Code B C ............ ..........

Procedure

Require replacement. Require replacement of

Attaching hardware threads damaged ................ Attaching hardware threads stripped (threads missing) ............... Code set (if applicable) ............ ........ ........

hardware. A ... Require repair or replacement of hardware. Require repair or replacement of hardware.

A A A A A A B A C A A 2 A 2 B 1 A A B A A A

...

Connector broken Connector melted

Connector missing ....... Contaminated ............ Inoperative ............. Leaking ................. Missing ................. Terminal broken ......... Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance .. Threads damaged ......... Threads stripped (threads missing) ............... Wire lead conductors exposed ................ Wire lead corroded ...... Wire lead open .......... Wire lead shorted .......

( 1) Further inspection required. .. Require repair or replacement. ........... ( 2) Require repair or replacement. ................. Require repair. .. Require repair or replacement. .. Require repair or replacement. (3) Further inspection required. .. Require repair or replacement. ............ Require replacement. .. Require repair or replacement. ........... .. .. .. .. .. .. ( 2) Require repair or replacement.

..........

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Require replacement. repair repair repair repair or or or or replacement. replacement. replacement. replacement.

............ .. .. .. .. Require Require Require Require

(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.

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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

Contaminated, for example, fluid that leaked from caliper, wheel cylinder, or axle seal ........... Cracked through ......... Flaking or chunking ..... Glazed (shiny) .......... Grooves or ridges .......

Permanently attached hardware bent .......... Permanently attached hardware broken ........ Permanently attached hardware loose ......... Permanently attached hardware missing ....... Permanently attached hardware seized ........ Rivets loose ............ Separating from backing . Shoe table or web bent .. Shoe table or web cracked ................ Shoe table or web worn, affecting performance .. Surface cracking ........

Tapered wear ............ Thickness of one pad is greater than opposite pad in the same caliper (uneven wear) ..........

Wear indicator device (electronic) contacts rotor .................. Wear indicator device (mechanical) bent ....... Wear indicator device (mechanical) broken ....

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Code A ........ ( 1) B B .. ........ No .. A A A C A B B B A .... Require Require Require service ............ ............ ............ ............ .. Require repair or ............ Require ............ Require ............ Require ............ .. .... B ...... .. .......... .. .........

Procedure

replacement. replacement. replacement. suggested or required. (2) No service suggested or required. Require replacement. Require replacement. Require replacement. Require replacement. replacement. replacement. replacement. replacement.

Require replacement.

A ............ Require replacement. .. ........ No service suggested or required. Further inspection may be necessary to determine cause. B ........ ( 3) Suggest replacement.

(4) Replacement of friction material not suggested or required. Further inspection required. See CALIPERS and CALIPER HARDWARE. (5) Require replacement of appropriate parts. ( 6) Further inspection required. ( 6) Further inspection required.

Wear indicator device (mechanical) contacts rotor .................. Worn close to minimum specifications ......... Worn to, or below minimum specifications .........

.. 1 B

......... ........

( 6) Further inspection required. ( 7) Suggest replacement. 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.

HOSE INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............. Blistered ............... Fitting threads damaged . Fitting threads stripped (threads missing) ...... Incorrectly secured ..... Inner fabric (webbing) cut .......... Leaking ................. Missing ................. Outer covering is cracked to the extent that inner fabric of hose

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G SENSORS
See ACCELEROMETERS.

HOSES

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Code A C A B A A B B A C ... .......... ... ............ ............ ............

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. ............ Require replacement. .. Require repair or replacement. ............ Require replacement. ................. Require repair. Require replacement. Require replacement. Require replacement.

is visible ............. Restricted .............. Routed incorrectly ......

B A B

............ Require replacement. ............ Require replacement. ................. Require repair.

NOTE:

HYDRAULIC MODULATOR INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Connector broken ........ Connector (Weatherpack type) leaking .......... Connector melted ........ Connector missing ....... Disabled ................ Electrical failure ...... External leak ........... Housing cracked ......... Inoperative (2) ......... Internal leak ........... Missing ................. Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance .. Threads damaged ......... Threads stripped (threads missing) ............... Valve stuck ............. Wire lead burned ........ Wire lead conductors exposed ................ Wire lead open .......... Wire lead shorted .......

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

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HYDRAULIC MODULATORS
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.

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Code A C A A A A C A A A B A A C A 2 A 2 B 1 A A A A B A A ... .......... ... .. .. Require repair or ........ ( 1) Require ............ Require .. Require repair or .. Require repair or .. Require repair or .. Require repair or .. Require repair or .. Require repair or ............ Require ........... .. .. .. .. .. .. .. .. ..

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require repair or replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement. replacement.

( 1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement.

............ Require replacement. .. Require repair or replacement. .. Require repair or replacement. Require repair or replacement. Require repair or replacement. Require repair or replacement.

NOTE:

HYDRO-BOOSTER INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Connector broken ........ Connector (Weatherpack type) leaking .......... Connector melted ........ Connector missing ....... Does not apply assist, or inadequate assist ...... Leaking ................. Leaks fluid at fitting .. Leaks fluid at unit ..... Leaks fluid from pressure hose(s) ................ Leaks fluid into passenger compartment ............ Threads damaged ......... Terminal burned, affecting performance ............ Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance .. Threads stripped (threads missing) ...............

(1) - Determine cause and correct prior to replacement of part.

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HYDRO-BOOSTERS
Hydro-boosters and hydro-electric boosters are combined.

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Code A C A A A A C A B B B B B A A 2 A 2 B 1 A ... .......... ... .. . .. .. ........... .. .. .. .. .. ............

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require repair or replacement.

.. Require repair or replacement. ........ ( 1) Require replacement. ............ Require replacement. .. Require repair or replacement. .. Require repair or replacement. ........... Require tightening or replacement. .. Require repair or replacement. Require replacement of hose(s). Require repair or replacement. Require repair or replacement. ( 1) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require replacement.

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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

Application incorrect ... Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Broken, affecting performance ............ Broken, not affecting performance ............ Cracked ................. Discolored .............. Leaking ................. Melted, affecting performance ............ Melted, not affecting performance ............ Missing .................

MASTER CYLINDER INSPECTION Condition

Brake fluid leaking from rear of master cylinder bore ................... Brake pedal drops intermittently ......... Fluid level low .........

Internal valve failure .. Master cylinder leaking brake fluid internally . Piston does not return .. Ports plugged ........... Rubber master cylinder cover gasket distorted and gummy ..............

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Code A A C A A .. A A A A 2 C ............ ... .......... ... ............ ........ ............ ............ ............

Procedure

Require replacement.

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require replacement.

No service suggested or required. ............ Require replacement. ............ Require replacement. .. Require repair or replacement. Require replacement. Suggest replacement. Require replacement.

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MASTER CYLINDERS

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Code B A .. ........... A A A A .. .. .. ..

Procedure

Require repair or replacement.

( 1) Require repair or replacement. .. ......... ( 2) Further inspection required. A .. Require repair or replacement. Require repair or replacement. Require repair or replacement. Require repair or replacement. (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.

NOTE:

PARKING BRAKE SYSTEM INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Cable improperly adjusted ............... Cable or individual wires in the cable are broken ............. Cable sticking .......... Cable stuck inside conduit and cannot be lubricated so that parking brake functions properly ..... Inoperative (1) .........

Parking brake parts bent ............. Parking brake parts broken ...........

Parking brake parts

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MODULATORS
See HYDRAULIC MODULATORS.

MOTORS
See ELECTRICAL PUMPS AND MOTORS.

PARKING BRAKE SWITCHES
See SWITCHES.

PARKING BRAKE SYSTEMS
The parking brake is an integral part of the brake system. It is important that the parking brake function properly when brake service is performed.

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Code A C A B A A ... .......... ... ....... .... A A B A .... ... ...

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require cable adjustment.

Require replacement of cable assembly. ...... Require cable lubrication.

Require replacement of cable assembly. .......... Require replacement of inoperative parts. Require repair or replacement of bent parts. Require replacement of broken parts.

missing

................

C A A

.. ..

Threads damaged ......... Threads stripped (threads missing) ...............

Require replacement of missing parts. Require repair or replacement. Require replacement.

............

(1) - Inoperative includes intermittent operation.

NOTE:

RELAY INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Housing broken .......... Housing cracked ......... Inoperative (1) ......... Missing ................. Terminal broken ......... Terminal burned, affecting performance ..

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PADS
See FRICTION MATERIAL.

PEDAL TRAVEL SWITCHES
See SWITCHES.

PEDALS
See BRAKE PEDALS.

POWERMASTER
See HYDRO-BOOSTERS.

PUMPS
See ELECTRICAL PUMPS AND MOTORS.

PRESSURE DIFFERENTIAL SWITCHES
See SWITCHES.

PRESSURE SWITCHES
See SWITCHES.

RELAYS
Copied from Electrical UIGs

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Code A C A A 2 A C A A ... .......... ... ...........

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. ............ Require replacement. ............ Suggest replacement. ............ Require replacement. ............ Require replacement. .. Require repair or replacement. ( 2) Require repair or replacement.

Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance ............ Terminal loose, not affecting performance ..

2 A 2 B 1

.. .. .. .. ..

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement.

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

Determine the need to recondition based upon individual rotor conditions that follow. Friction material replacement does not require rotor reconditioning unless other justifications exist. DO NOT recondition new rotors unless they are being pressed or bolted onto an existing hub. It is not necessary to replace rotors in axle sets. However, when replacing or reconditioning a rotor due to the conditions that follow, you may suggest reconditioning of the other rotor on the same axle to eliminate uneven braking behavior. Determine the need to replace based upon the individual rotor conditions that follow. Reconditioning is defined as machining and block sanding, or block sanding only. Block sanding is defined as using 120-150 grit sandpaper with moderate to heavy force for 60 seconds per side. Always wash rotors after servicing or before installing. ROTOR INSPECTION Condition

Corrosion affecting structural integrity ... Cracked ................. Hard spots .............. Lateral runout (wobble) exceeds OEM specifications .........

Measured thickness is less than OEM discard specifications ......... B Rotor thickness is less than OEM "machine to" specifications but thicker than "discard at" specifications, and the rotor does not require reconditioning ......... 1 Rotor thickness will be less than OEM "machine to" specifications after required

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ROTORS

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Code A B 2 B ............ ........

Procedure

........ ( 1) Require replacement. ............ Require replacement. ....... Suggest reconditioning or replacement of rotor according to OEM specifications. ............ Require re-indexing, reconditioning, or replacement according to specifications. Require replacement.

( 2) Suggest replacement.

reconditioning ......... Surface is rust-pitted .. Surface is scored .......

B B B

Thickness variation (parallelism) exceeds OEM specifications ..........

........ ( 3) Require replacement. ....... Require reconditioning or replacement of rotor according to OEM specifications. ... (4) Require reconditioning or replacement of rotor according to OEM specifications. ....... Require reconditioning or replacement of rotor according to OEM specifications.

B

(1) - Examples of severe corrosion are: composite plate separated from friction surfaces and cooling fins cracked or missing. (2) - Only applies to vehicles for which OEM "machine to" specifications exist. If OEM does not supply "machine to" specifications, the rotor may be worn to discard specifications. (3) - If OEM does not supply "machine to" specifications, you may machine to discard specifications. (4) - Scoring is defined as grooves or ridges in the friction contact surface. Some vehicle manufacturers require machining when scoring exceeds their allowable specifications.

SELF-ADJUSTING SYSTEM INSPECTION Condition Bent Broken

Inoperative Missing

Star wheel does not turn freely .................

(1) - Inoperative includes intermittent operation.

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SELF-ADJUSTING SYSTEMS

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Code A A A C A .................... .................. ............. ... ................. ..

Procedure

Require repair or replacement of bent part. ... Require repair or replacement of broken part. ........... ( 1) Require repair or replacement of inoperative parts. .......... Require replacement of missing part. Require repair or replacement.

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SHOE HARDWARE
See BRAKE SHOE HARDWARE.

SHOES
See FRICTION MATERIAL.

SOCKETS
See BULB SOCKETS.

SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)

NOTE:

Copied Vehicle Speed Sensors from Engine UIGs & added Air Gap incorrect, loose, and wire lead misrouted. For "contaminated" removed coolant & fuel examples from note.

SPEED SENSOR INSPECTION Condition

Air gap incorrect

Attaching hardware missing ................ Attaching hardware threads damaged ........ Attaching hardware threads stripped (threads missing)

Connector broken ........ Connector (Weatherpack type) leaking ........... Connector melted ........ Connector missing ....... Contaminated ............ Inoperative ............. ..

Lead routing incorrect

Leaking ................. Loose ................... Missing ................. Resistance out of specification .......... Sensor housing cracked .. Terminal broken ......... Terminal burned, affecting performance .. Terminal burned, not affecting performance .. Terminal corroded, affecting performance .. Terminal corroded, not affecting performance .. Terminal loose, affecting performance .. Terminal loose, not affecting performance .. Threads damaged ......... Threads stripped (threads missing) ...... Wire lead conductors exposed ................ Wire lead corroded ...... Wire lead misrouted .....

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Code B C A ....... ....... .......... ... ...... A A A A C A B B A A C B 2 A A 2 A 2 B 1 A A B A B .. .. ........... .. .. .. .. .. .. ............

Procedure

( 1) Require adjustment or replacement. Require replacement of hardware.

Require repair or replacement of hardware. Require repair or replacement of hardware. Require repair or replacement.

.. Require repair or replacement. ........... ( 2) Require repair or replacement. ............ Require replacement. ........... ( 3) Require repair or replacement. ........... ( 4) Require repair or replacement. Further inspection required. ..... Require rerouting according to vehicle manufacturer's specifications. .. Require repair or replacement. .. Require repair or replacement. ............ Require replacement. .. Require repair or replacement. ............ Suggest replacement. .. Require repair or replacement. ( 2) Require repair or replacement.

Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Suggest repair or replacement. Require repair or replacement. Require replacement.

.. Require repair or replacement. .. Require repair or replacement. . Require re-routing according to vehicle manufacturer's

Wire lead open .......... Wire lead shorted .......

A A

.. ..

specifications. Require repair or replacement. Require repair or replacement.

(1) - If a sensor is not adjustable, further inspection is required to identify and correct cause. (2) - Determine cause and correct prior to repair or replacement of part. (3) - Determine source of contamination, such as metal particles or water. Require repair or replacement. (4) - Inoperative includes intermittent operation or out of OEM specification. Some components may be serviceable; check for accepted cleaning procedure.

STEEL BRAKE LINE INSPECTION Condition

Attaching hardware broken ................. Attaching hardware missing ................ Attaching hardware not functioning ............ Corroded, affecting structural integrity ... Fitting incorrect (for example, compression fitting) ............... Flare type incorrect .... Leaking ................. Line material incorrect (copper, etc.) ......... Restricted .............. Routed incorrectly ...... Rust-pitted ............. Threads damaged ......... Threads stripped (threads missing) ......

NOTE:

STEEL BRAKE LINE INSPECTION Condition

Attaching hardware broken .................

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STEEL BRAKE LINES

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Code A C A A B B A B A B 1 A A ... .......... ... ............ ............

Procedure

Require repair or replacement of hardware. Require replacement of hardware.

Require repair or replacement of hardware. Require replacement.

............ Require replacement. .. Require repair or replacement. .. Require repair or replacement. ............ Require replacement. ............ Require replacement. ..... Require routing correction. ............ Suggest replacement. .. Require repair or replacement. Require replacement.