MAP Drive Train & Transmission

1998 Chevrolet Pickup C1500
Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION
Uniform Inspection and Communication Standards
DRIVE TRAIN AND TRANSMISSION
OVERVIEW
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, Electrical Systems, and Drive Train and Transmissions. Further,
revisions to all of these inspection communication standards are continually re-published. Participating shops
utilize these Uniform Inspection & Communication Standards as part of the inspection process and for
communicating their findings to their customers.
The Motorist Assurance Program continues to work cooperatively and proactively with government agencies
and consumer groups toward solutions that both benefit the customer and are mutually acceptable to both
regulators and industry. We maintain the belief that industry must retain control over how we conduct our
business, and we must be viewed as part of the solution and not part of the problem. Meetings with state and
other government officials (and their representatives), concerned with auto repair and/or consumer protection,
are conducted. Feedback from these sessions is brought back to the association, and the program adjusted as
needed.
To assure auto repair customers recourse if they were not satisfied with a repair transaction, the Motorist
Assurance Program offers mediation and arbitration through the Better Business Bureau and other non-profit
organizations. MAP conducted pilot programs in twelve states before announcing the program nationally in
October 1998. During the pilots, participating repair shops demonstrated their adherence to the Pledge and
Standards and agreed to follow the UICS in communicating the results of their inspection to their customers.
To put some "teeth" in the program, an accreditation requirement for shops was initiated. The requirements are
stringent, and a self-policing method has been incorporated which includes the "mystery shopping" of outlets.
We welcome you to join us as we continue our outreach with your support, both the automotive repair industry
and your customers will reap the benefits. Please visit MAP at our Internet site www.motorist.org or contact us
at:
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Tuesday, November 08, 2005 3:11:07
3:11:02 PM Page 1 © 2004 Mitchell Repair Information Company, LLC.
7101 Wisconsin Avenue
Bethesda, MD 20814
Phone (301) 634-4955 - Fax (202) 318-0378
January 2002
[email protected]
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.
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Tuesday, November 08, 2005 3:11:02 PM Page 2 © 2004 Mitchell Repair Information Company, LLC.
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: IMPORTANT -When a procedure states that a required or suggested repair or

replacement is recommended, the basis for the recommendation MUST be
explained to the customer. If the customer asks whether there are alternatives
to the recommendation, generally acceptable repair/replacement options must
be explained, whether performed or not by the shop.
NOTE: 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.
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DRIVE/POWER TRAIN ASSEMBLIES
NOTE: Whenever transmission or drivetrain service is performed that affects the

suspension alignment, for example, removing the engine cradle, it is required
that the alignment be checked and corrected if necessary.
AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES

Automatic Transmission/Transaxle Assemblies
Condition Code Procedure
Any internal component failure that A Require repair or replacement of the
requires removal of the assembly from automatic transmission/transaxle
the vehicle for service. See note below. assembly. See note below.
NOTE: It is Required that the torque converter and all other failure-related components
be inspected for cause and condition.
NOTE: For components not requiring removal of the assembly, refer to the component
listing in this document.
DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES
NOTE: Does not include half shafts.
Differential and Final Drive Assemblies

Any internal component failure that requires A Require repair or replacement
removal of the assembly from the vehicle for of the differential assembly.
service. See note below.
MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES

Manual Transmission/Transaxle Assemblies
Any internal component failure that A Require repair or replacement of the
requires removal of the assembly from the manual transmission/transaxle
vehicle for service. See note below. assembly.
TRANSFER CASE ASSEMBLIES
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Transfer Case Assemblies

Any internal component failure that requires A Require repair or replacement of
removal of the assembly from the vehicle for the transfer case differential
service. See note below. assembly.
NOTE: For components not requiring remoaval of the assembly, refer to the component
DRIVE/POWER TRAIN COMPONENTS

The conditions listed for the components included in this section assume that the problem has been isolated to
the specific component through proper testing.
ACTUATORS (ELECTRICAL)
Actuators (Electrical)
Attaching hardware broken A Require repair or replacement of
hardware.
Attaching hardware missing C Require replacement of hardware.
Attaching hardware not functioning A Require repair or replacement of
hardware.
Connector broken A Require repair or replacement.
Connector (Weatherpack type) leaking A Require repair or replacement.
Connector melted, affecting A Require repair or replacement. See note
performance below.
NOTE: Determine cause and correct prior to repair or replacement of part.
Connector melted, not affecting 2 Suggest repair or replacement. See note
performance below.
Connector missing C Require replacement.
Inoperative A Require replacement. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification.
Missing C Require replacement.
Noisy 2 Suggest repair or replacement.
Out of adjustment B Require repair or replacement.
Terminal broken A Require repair or replacement.
Terminal burned, affecting performance A Require repair or replacement. See note
below.
Terminal burned, not affecting 1 Suggest repair or replacement. See note
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performance below.
Terminal corroded, affecting A Require repair or replacement.
performance
Terminal corroded, not affecting 1 Suggest repair or replacement.
performance
Terminal loose, affecting performance B Require repair or replacement.
Terminal loose, not affecting 1 Suggest repair or replacement.
performance
ACTUATORS (VACUUM)
Actuators (Vacuum)
hardware.
hardware.
Connector melted, affecting A Require repair or replacement. See note
performance below.
Connector melted, not affecting 2 Suggest repair or replacement. See note
performance below.
Leaking (vacuum) A Require repair or replacement.
Linkage bent, affecting performance A Require repair or replacement of linkage.
Linkage bent, not affecting performance 2 Suggest repair or replacement of linkage.
Linkage binding, affecting performance A Require repair or replacement of linkage.
Linkage binding, not affecting 1 Suggest repair or replacement of linkage.
performance
Linkage broken A Require repair or replacement of linkage.
Linkage loose, affecting performance A Require repair or replacement of linkage.
Linkage loose, not affecting 1 Suggest repair or replacement of linkage.
performance
Linkage missing C Require replacement.
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Linkage noisy 2 Suggest repair or replacement.

Out of adjustment A Require repair or replacement.
below.
Terminal burned, not affecting 2 Suggest repair or replacement.
performance
performance
performance
performance
AXLES
Axles
Bent A Require replacement.
Broken A Require replacement.
End play exceeds specifications B Require repair or replacement.
Flange bent A Require replacement.
Flange threads stripped A Require repair or replacement.
Twisted A Require replacement.
Worn, affecting performance A Require replacement.
BEARINGS AND RACES
NOTE: When replacing or repacking bearings, grease seal replacement is required.

You are not required to replace these components in axle sets. Determine the
need to replace based upon the individual component conditions that follow.
Bearings and Races

Bearing end-play exceeds B Require adjustment of bearing, if possible. If
specifications proper adjustment cannot be obtained, require
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replacement of bearing assembly.

Bearing rollers, balls or races are B Require replacement of bearing assembly.
worn, pitted, or feel rough when
rotated as an assembly
BELL CRANKS
Bell Cranks
Attaching hardware broken A Require repair or replacement of hardware.
Attaching hardware not functioning A Require repair or replacement of hardware.
Bent A Require repair or replacement.
Broken A Require repair or replacement.
Cracked A Require repair or replacement.
Worn, affecting performance A Require repair or replacement.
BELL HOUSINGS
See Housings (Bell, Case, Tail (Extension) and Auxiliary).
BUSHINGS (EXTERNAL)
Bushings (External)
Attaching hardware bent B Require repair or replacement of bent part if
available; otherwise, replace bushing.
Attaching hardware broken A Require replacement of broken part if available;
otherwise, replace bushing.
Attaching hardware corroded, A Require replacement of corroded part if
affecting structural integrity available; otherwise, replace bushing.
Attaching hardware incorrect A Require replacement of incorrect part if
Attaching hardware loose A Require repair or replacement of loose part if
Attaching hardware missing C Require replacement of missing part if
Attaching hardware threads A Require repair or replacement of part with
damaged damaged threads if available; otherwise, replace
bushing.
Attaching hardware threads A Require replacement of part with stripped
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stripped (threads missing) threads if available; otherwise, replace bushing.

Binding A Require repair or replacement.
Contaminated 1 Suggest replacement.
Deteriorated, affecting A Require repair or replacement.
performance
Distorted, affecting performance A Require repair or replacement.
Noisy 2 Further inspection required. See note and
caution below.
NOTE: If noise isolated to bushing, suggest repair or replacement.
CAUTION: Use only approved lubricant on rubber bushings. Petroleum-based
lubricants may damage rubber bushings.
Rubber separating from internal A Require replacement.
metal sleeve on bonded bushing
Seized A Require replacement.
Shifted (out of position) B Require repair or replacement.
Split A Require replacement.
Surface cracking (weather- 4 No service suggested or required.
checked)
Worn close to the end of its useful 1 Suggest replacement.
life
CABLES (SPEEDOMETER)
Cables (Speedometer)
hardware.
hardware.
Bracket bent, affecting performance A Require repair or replacement.
Bracket bent, not affecting performance No service suggested or required.
Bracket broken, affecting performance A Require replacement.
Bracket broken, not affecting No service suggested or required.
performance
Bracket corroded, affecting A Require repair or replacement.
performance
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Bracket corroded, not affecting 2 Suggest repair or replacement.

performance
Bracket cracked, affecting performance A Require repair or replacement.
Bracket cracked, not affecting 1 Suggest repair or replacement.
performance
Bracket loose, affecting performance A Require repair or replacement.
Bracket loose, not affecting 1 Suggest repair or replacement.
performance
Bracket missing C Require replacement.
Disconnected A Require repair or replacement.
Kinked A Require repair or replacement.
Melted A Require repair or replacement. See note
below.
Routed incorrectly 2 Suggest repair.
Seized A Require repair or replacement.
CABLES (TV, DETENT, AND SHIFT)

Cables (TV, Detent, and Shift)
hardware.
hardware.
Bracket bent, affecting performance A Require repair or replacement.
Bracket bent, not affecting performance 2 No service suggested or required.
Bracket broken, not affecting 2 No service suggested or required.
performance
Bracket corroded, affecting A Require repair or replacement.
performance
Bracket corroded, not affecting 2 Suggest repair or replacement.
performance
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Bracket cracked, affecting performance A Require repair or replacement.

Bracket cracked, not affecting 1 Suggest repair or replacement.
performance
Bracket loose, affecting performance A Require repair or replacement.
Bracket loose, not affecting 1 Suggest repair or replacement.
performance
Disconnected A Require repair or replacement.
Frayed A Require replacement.
Kinked A Require repair or replacement.
Melted A Require repair or replacement. See note
below.
Out of adjustment B Require repair or replacement See note
below.
Note: Cable replacement is required if it cannot be adjusted within specifications.
Routed incorrectly 2 Suggest repair.
Seized A Require repair or replacement.
Self-adjuster inoperative A Require repair or replacement of self-
adjuster.
Threads damaged A Require repair or replacement.
Threads stripped (threads missing) A Require replacement.
CARRIER BEARINGS
See Intermediate Shaft Support Bearings
CLUTCH CABLES AND CABLE HOUSINGS

Clutch Cables and Cable Housings
Cable bent A Require replacement.
Cable binding A Require repair or replacement.
Cable mounting loose B Require repair or replacement.
Cable out of adjustment B Require repair or replacement.
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Frayed B Require replacement.

Housing heat-damaged 1 Suggest replacement.
CLUTCH DISCS (MANUAL TRANSMISSION)

Clutch Discs (Manual Transmission)
Backing plate cracked A Require replacement.
Contaminated with oil A Require replacement.
Damper cushion broken A Require replacement.
Damper cushion A Require replacement.
collapsed
Damper spring A Require replacement.
collapsed
Damper spring missing C Require replacement. See note below.
NOTE: Not all clutch discs have springs in all spring chambers on the disc.
Friction material B Require replacement.
cracked through
Friction material flaking B Require replacement.
or chunking
Friction material surface No service suggested or required.
cracking
Grooved B No service suggested or required unless the pressure plate
or flywheel is being resurfaced or replaced. In this case,
replacement of clutch disc is required.
Ridged B No service suggested or required unless the pressure plate
or flywheel is being resurfaced or replaced. In this case,
replacement of clutch disc is required.
Splines worn, affecting A Require replacement.
performance
Warped A Require replacement.
Wear exceeds B Require replacement.
specifications (where
applicable)
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Worn close to the end of 1 Suggest replacement.

its useful life
Worn, affecting A Require replacement.
performance
CLUTCH FORKS
Clutch Forks
Bent B Require replacement.
Cracked B Require repair or replacement.
Worn close to the end of its useful life 1 Suggest replacement.
CLUTCH LINKAGES (MECHANICAL)

See Linkages (External).
CLUTCH MASTER CYLINDERS

Clutch Master Cylinders
Cover gasket distorted A Require replacement of cover gasket.
Cover gasket gummy A Require replacement of cover gasket.
Cylinder leaking fluid from rear of A Require repair or replacement.
bore
Cylinder leaking fluid internally A Require replacement.
Dust boot missing C Require replacement of dust boot.
Dust boot punctured A Require replacement of dust boot.
Dust boot torn A Require replacement of dust boot.
Fluid level incorrect B Require fluid level adjustment.
Housing damaged, affecting A Require repair or replacement.
performance
Master cylinder has residue in 2 Further inspection required. See note
reservoir below.
NOTE: Do not replace master cylinder unless it exhibits conditions listed for
replacement. You may suggest fluid change according to OEM service intervals.
Threads damaged A Require repair replacement
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CLUTCH PEDALS
Clutch Pedals
Bent, affecting performance A Require repair or replacement.
Pedal pad missing C Require replacement of pedal pad.
Pivot bushings worn, affecting A Require replacement of pivot
performance bushings.
CLUTCH PIVOTS
Clutch Pivots
CLUTCH PRESSURE PLATES

See Pressure Plates.
CLUTCH RELEASE BEARINGS

Clutch Release Bearings
Collar broken A Require replacement.
Cracked A Require replacement.
Rough when rotated as an assembly B Require replacement.
Wear exceeds specifications B Require replacement.
CLUTCH SLAVE CYLINDERS (CONCENTRIC)

Clutch Slave Cylinders (Concentric)
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Bearing rough when rotated as an assembly B Require replacement.
Bearing seized A Require replacement.
Bleeder pipe leaks A Require repair or replacement.
Carrier assembly worn, affecting performance A Require replacement.
Collar broken A Require replacement.
Housing leaks A Require replacement.
Inoperative A Require replacement.
Release binding A Require replacement.
Spring broken A Require replacement.
CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

Clutch Slave Cylinders (Conventional or External)
Bleeder port damaged (not repairable) A Require replacement. See note below.
NOTE: Only required if the hydraulic system must be opened.
Bleeder port damaged (repairable) A Require repair. See note below.
Bleeder screw broken off in slave A Require replacement. See note below.
cylinder
Bleeder screw seized A Require replacement. See note below.
NOTE: Seized is defined as a bleeder screw that cannot be removed after a practical
attempt at removing it has been made.
Bore corroded (pitted) B Require replacement.
Bore grooved A Require replacement.
COMPANION FLANGES
See Yokes and Slip Yokes.
CONNECTORS
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See Wiring Harnesses and Connectors.
COOLER BYPASS VALVES

Cooler Bypass Valves
Inoperative A Require replacement.
Installed incorrectly A Require repair.
Leaking A Require repair or replacement.
Restricted A Require repair or replacement.
COOLER LINES
Cooler Lines
Abrasion damage, affecting structural integrity A Require repair or replacement.
Abrasion damage, not affecting structural No service suggested or
integrity required.
Application incorrect B Require replacement.
hardware.
Attaching hardware missing C Require replacement of
hardware.
hardware.
Clamp corroded, not reusable 1 Suggest replacement. See note
below.
NOTE: If clamp removed, require replacement
Connected incorrectly A Require repair.
Corroded, affecting structural integrity A Require replacement.
Corroded, not affecting structural integrity No service suggested or
required.
Fitting type incorrect (such as compression B Require replacement.
fitting)
Flange leaking A Require repair or replacement.
Insufficient clamping force, allowing hose to A Require repair or replacement.
leak
Melted 1 Suggest repair or replacement.
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Outer covering damaged to the extent that the A Require replacement.

inner fabric is visible
Protective sleeves damaged 2 Suggest replacement of sleeves.
Protective sleeves missing C Require replacement of sleeves.
Restricted, affecting performance A Require repair or replacement.
Routed incorrectly B Require repair.
Swollen 1 Suggest replacement.
Type incorrect 1 Suggest repair or replacement.
COOLERS
See Transmission Coolers.
CV JOINTS
CV Joints
Bearing, bushing or seal surface worn, A Require repair or replacement.
affecting performance
Boot clamp broken A Require repair or replacement of
clamp.
Boot clamp loose A Require repair or replacement of
clamp.
Boot clamp missing C Require repair or replacement of
clamp.
Boot leaking A Require replacement of CV boot.
See note below.
NOTE: Further inspection of joint required before replacing boot.
Boot surface cracked, not leaking 2 Suggest replacement of CV boot.
Cage broken A Require repair or replacement of
CV joint.
Housing damaged to the extent that it no A Require repair or replacement of
longer performs its intended function CV joint. See note below.
NOTE: Housing assembly may appear blue in color from normal manufacturing process
of heat-treating the housing.
Housing worn to the extent that it no longer A Require repair or replacement of
performs its intended function CV joint. (See note below.
NOTE: Housing assembly may appear blue in color from normal manufacturing process
of heat-treating the housing.
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Holes elongated A Require replacement.

Internal parts binding A Require repair or replacement.
Internal parts worn A Require repair or replacement.
Lubricant missing C Require cleaning, inspection, and
repacking of CV joint.
DIP STICK TUBES

Dip Stick Tubes
Checkball missing C Suggest repair or replacement.
Hold down bracket broken A Require repair or replacement.
Hold down bracket missing C Require replacement.
DIP STICKS (FLUID LEVEL INDICATORS)

Dip Sticks (Fluid Level Indicators)
Compressed A Require repair or replacement.
Modified A Require replacement.
Stretched A Require repair or replacement.
DOWEL PINS, GUIDES, AND PILOT HOLES

Dowel Pins, Guides, and Pilot Holes
Application incorrect B Require repair or
replacement.
Cracked A Require repair or
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replacement.
Distorted A Require repair or
replacement.
Positioned incorrectly B Require repair or
replacement.
Stepped A Require repair or
replacement.
Worn to the extent that it no longer performs its A Require repair or
intended function replacement.
DRIVE SHAFT FLANGES

See Companion Flanges.
DRIVE SHAFTS AND HALF SHAFTS

Drive Shafts and Half Shafts
Balance weight missing C Require repair or replacement.
Bearing cap bore distorted A Require repair or replacement.
Bolt holes elongated A Require repair or replacement.
Bushing or seal surface worn, affecting A Require repair or replacement.
performance
Leaking through soft yoke plug A Require repair or replacement
of soft yoke plug.
Out of balance A Require repair or replacement.
Retainer strap bent A Require replacement of retainer
strap.
Slip yoke broken A Require replacement.
Splines worn, affecting performance A Require replacement.
Splines worn, not affecting performance, but 1 Suggest repair or replacement.
close to the end of their useful life
U-bolt damaged, affecting performance A Require replacement of U-bolts.
Yoke damaged, affecting performance A Require repair or replacement
of yoke.
DUST BOOTS
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NOTE: Does not include CV boots.
Dust Boots
Cracked, not leaking 1 Suggest replacement.
Torn A Require replacement.
Weather checked, surface cracked No service suggested or required.
ENGINE MOUNTS
See Mounts (Engine, Transaxle, and Transmission).
EXCITER RINGS
See Toothed Rings (Tone Wheels).
FILLER TUBES
See Dip Stick Tubes.
FILTERS AND SCREENS

Filters and Screens
At service interval 3 Suggest replacement.
Exceeding service interval 3 Suggest replacement.
Near service interval 3 Suggest replacement.
Restricted A Require repair or replacement. See
note below.
NOTE: Further inspection may be required to determine the source of restriction or
contamination.
Torn A Require replacement.
Worn, affecting performance (metal or nylon A Require repair or replacement.
screen type)
FLANGES
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See Companion Flanges.
FLEX PLATES
Flex Plates
Bent, affecting performance A Require replacement.
Bent, not affecting performance No service suggested or
required.
Bolt or stud holes elongated B Require replacement.
Ring gear worn close to the end of its useful life 1 Suggest replacement.
Ring gear worn to the extent that it no longer performs A Require replacement.
its intended function
Weights missing A Require repair or
replacement.
FLUID LEVEL INDICATORS

See Dip Sticks (Fluid Level Indicators).
FLUIDS AND LUBRICANTS

Fluids and Lubricants
Application incorrect B Require replacement. See note
below.
NOTE: Determine and correct cause.
At service interval 3 Suggest replacement.
Beyond service interval 3 Suggest replacement.
Burned Further inspection required. See
note below.
NOTE: Fluid that is burned indicates a serious problem. Determine and correct the
cause.
Contaminated, for example, fluid other than A or B Require service. See note below.
hydraulic fluid present
NOTE: If a fluid other than the correctly specified fluid is present in the hydraulic
system which DOES affect the rubber parts, the required service is to: 1) remove all
components having rubber parts from the system, 2) flush lines with denatured alcohol
or hydraulic cleaner, 3) repair or replace all components having rubber parts, and 4)
bleed and flush with correct hydraulic fluid. (Code A)
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system which DOES NOT affect the rubber parts, the required service is to flush and fill
with the correct hydraulic fluid. (Code B)
Exceeding service interval 3 Suggest replacement.
Hydraulic fluid incorrect B Require service. See note below.
NOTE: If a fluid other than specification hydraulic fluid is present in the hydraulic
system, the required service is to flush and fill with the correct hydraulic fluid.
Level incorrect B Require correction of fluid level.
Near service interval 3 Suggest replacement.
Rubber master cylinder cover gasket distorted A Require service. See note below.
and gummy
system which DOES affect the rubber parts, the required service is to: 1) remove all
components having rubber parts from the system, 2) flush lines with denatured alcohol
or hydraulic cleaner, 3) repair or replace all components having rubber parts, and 4)
bleed and flush with correct hydraulic fluid.
Varnished Further inspection required. See
note below.
Note: Fluid that is varnished may indicate a serious problem. Determine and correct the
cause.
FLYWHEELS
NOTE: Clutch disc replacement does not necessitate flywheel reconditioning, unless
other conditions justify the reason to do so.
Flywheels
hardware.
hardware.
Cracked (other than mounting area) A Require resurfacing or
replacement. See note below.
NOTE: Some manufacturers allow slight surface cracking in the friction surface.
Cracks in mounting area B Require replacement.
Hard spots B Require repair or replacement.
Ring gear broken A Require replacement of ring gear .
Ring gear teeth worn, affecting performance A Require replacement of ring gear.
Runout exceeds specifications B Require repair or replacement.
Scored B Require repair or replacement.
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Surface cracks after resurfacing to B Require replacement.

manufacturer's minimum specifications
Wear exceeds specifications B Require replacement.
Worn, not affecting performance, but close to 1 Suggest repair or replacement.
the end of its useful life
FORCE MOTORS
See Actuators (Electrical).
GUIDES
See Dowel Pins, Guides, and Pilot Holes.
HALF SHAFTS
See Drive Shafts and Half Shafts
HOSES, LINES, AND TUBES

Hoses, Lines, and Tubes
Connected incorrectly A Require repair.
Corroded, not reusable 1 Suggest replacement.
Cracked line or tube A Require replacement.
Surface cracked (weather-checked) 1 Suggest repair or
replacement.
Hard hose 1 Suggest replacement.
Inner fabric (webbing) damaged A Require replacement.
Insufficient clamping force, allowing hose to leak A Require repair or
replacement.
Leaking A Require repair or
replacement.
Maintenance intervals 3 Suggest replacement.
Melted 1 Suggest repair or
replacement.
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Outer covering damaged 1 Suggest replacement.

Outer covering damaged to the extent that the inner A Require replacement.
fabric is visible
Protective sleeves damaged 2 Suggest replacement of
sleeves.
Protective sleeves missing 2 Suggest replacement of
sleeves.
Restricted, affecting performance A Require repair or
replacement.
Restricted, not affecting performance 2 Suggest repair or
replacement.
Routed incorrectly 2 Suggest replacement.
Safety clip missing C Require replacement.
Spongy 1 Suggest repair or
replacement.
Stripped A Require replacement.
Swollen B Require replacement.
Threads damaged A Require repair or
replacement.
Type incorrect 1 Suggest repair or
replacement.
HOUSINGS (BELL, CASE, TAIL (EXTENSION) AND AUXILIARY)

Housings (Bell, Case, Tail (Extension) and Auxiliary)
Bearing race loose in bore A Require repair or replacement.
Broken, affecting performance A Require repair or replacement.
Dowel pin holes worn, affecting performance See Dowel Pins, Guides, and Pilot
Holes.
Machined surfaces damaged, affecting A Require repair or replacement.
performance
INTERMEDIATE SHAFT SUPPORT BEARINGS

Intermediate Shaft Support Bearings
Home

Attaching hardware broken A Require repair or
replacement of hardware.
Attaching hardware missing C Require replacement of
hardware.
Attaching hardware not functioning A Require repair or
replacement of hardware.
Bearing rollers, balls or races are worn, pitted, noisy, A Require replacement of
or feel rough when rotated as an assembly bearing assembly.
Bracket bent, affecting performance A Require repair or
replacement.
Bracket bent, not affecting performance No service suggested or
required.
Bracket broken, not affecting performance 2 Suggest repair or
replacement of bracket.
Bracket corroded, affecting performance A Require repair or
replacement.
Bracket corroded, not affecting performance 2 Suggest repair or
replacement.
Bracket cracked, affecting performance A Require repair or
replacement.
Bracket cracked, not affecting performance 1 Suggest repair or
replacement.
Bracket holes elongated, affecting performance A Require repair or
replacement.
Bracket holes elongated, not affecting performances) No service suggested or
required.
Bracket loose, affecting performance A Require repair or
replacement.
Bracket loose, not affecting performance 1 Suggest repair or
replacement.
Rough (brinelling, spalling) A Require replacement.
Rubber deteriorated, affecting performance A Require replacement.
KEY INTERLOCK SYSTEMS

See Shift Interlock Systems (Selector and Key Interlock Systems).
Home
LIMITED SLIPS
See Differential Assembly
LINES
See Hoses, Lines, and Tubes.
LINKAGES (EXTERNAL)
Linkages (External)
Components missing C Require replacement of missing
components.
Linkage bent, affecting performance A Require repair or replacement of
linkage.
Linkage bent, not affecting performance 2 Suggest repair or replacement of
linkage.
Linkage binding, affecting performance A Require repair or replacement of
linkage.
Linkage binding, not affecting performance 1 Suggest repair or replacement of
linkage.
Linkage broken A Require repair or replacement of
linkage.
Linkage loose, affecting performance A Require repair or replacement of
linkage.
Linkage loose, not affecting performance 1 Suggest repair or replacement of
linkage.
Linkage missing C Require replacement.
Linkage noisy 2 Suggest repair or replacement.
Worn to the extent that it no longer performs its A Require repair or replacement.
intended function
LOCKING HUB ASSEMBLIES

Locking Hub Assemblies
Inoperative A Require repair or replacement.
NOTE: Inoperative includes intermittent operation.
Loose A Require repair or replacement.
Seized in any position A Require repair or replacement.
Home
LOCKING HUB CONTROL KNOBS

Locking Hub Control Knobs
Damaged, affecting performance A Require replacement.
LUBRICANTS
See Fluids and Lubricants.
METAL-CLAD SEALS
See Seals.
METALASTIC JOINTS
See Rubber Joints (Metalastic).
MODULATOR PINS
Modulator Pins
MODULATORS
Modulators
Bent, affecting performance A Require replacement.
Contaminated (water, fuel, etc.) A Require replacement. See note below.
NOTE: Further inspection is required to determine the cause of the contamination
Housing cracked A Require replacement.
Leaking fluid externally A Require repair or replacement.
Leaking fluid internally A Require replacement.
Leaking vacuum A Require replacement.
Nipple broken A Require replacement.
Home

MOUNTS (ENGINE, TRANSAXLE, AND TRANSMISSION)

Mounts (Engine, Transaxle, and Transmission)
hardware.
hardware.
Leaking (hydraulic mount) A Require replacement.
Mounting hole worn, affecting A Require replacement.
performance
Mounting hole worn, not affecting No service suggested or required.
performance
Rubber deteriorated, affecting performance A Require replacement.
Rubber deteriorated, not affecting No service suggested or required.
performance
ODOMETER DRIVES (MECHANICAL)

See Speedometer/Odometer Drives (Mechanical).
ODOMETER HEADS (MECHANICAL)

See Speedometer/Odometer Heads (Mechanical).
OIL PANS
See Transmission Pans.
PANS
PILOT HOLES
Home
See Dowel Pins, Guides, and Pilot Holes.
PRESSURE PLATES
Pressure Plates
Balance weight missing C Require replacement.
Contact surface distorted B Require replacement.
Cracks B Require replacement.
Fingers bent A Require replacement.
Hard spots B Require replacement.
Scored B Require replacement.
Spring rate less than specifications B Require replacement.
Worn beyond specifications B Require replacement.
PRESSURE SWITCHES
See Switches.
RACES
See Bearings and Races.
RUBBER JOINTS (METALASTIC)

These joints may be found on half and/or drive shafts. They are usually found on European vehicles featuring a
three-lug drive flange. They may be equipped with a centering ball or pin.
Rubber Joints (Metalastic)

Drive flange bent A Require repair or replacement.
Drive flange damaged, affecting performance A Require replacement.
Rubber drive joint cracked 2 Suggest replacement.
Rubber drive joint damaged, affecting A Require replacement.
performance
Rubber drive joint split between mounting holes A Require replacement.
Rubber drive joint torn at mounting holes A Require replacement.
Rubber drive joint weather-cracked No service suggested or
Home
required.
SCREENS
See Filters and Screens.
SEALS
Seals
Leaking A Require repair or replacement. See note below.
NOTE: Require inspection of mating and sealing surface and repair or replace as
necessary. Check vent. A plugged vent may force fluid past the seal.
SEALS (METAL-CLAD)
See Seals.
SELECTOR INTERLOCK SYSTEMS

See Shift Interlock Systems (Selector and Key Interlock Systems).
SERVOS
See Actuators (Vacuum).
SHIFT INTERLOCK SYSTEMS (SELECTOR AND KEY INTERLOCK

SYSTEMS)
See: Actuators (Electrical), Cables, Linkages (External), Switches.
SENSORS
Sensors
hardware.
hardware.
Home
Connector melted A Require repair or replacement. See note

below.
Inoperative A Require repair or replacement. See note
below.
NOTE: Inoperative includes intermittent operation or out of specification.
Leaking (vacuum/fluid/air) A Require replacement.
Out of adjustment B Further inspection required. See note
below.
NOTE: Follow OEM recommended adjustment procedures. Repair or replace if out of
specification.
below.
performance
performance
performance
performance
SIDE COVERS
SLIP YOKES
See Yokes and Slip Yokes.
SOLENOIDS
See: Actuators (Electrical), Actuators (Vacuum).
SPEED SENSORS (ELECTRONIC WHEEL AND VEHICLE)
Home
Speed Sensors (Electronic Wheel and Vehicle)

Air gap incorrect B Require adjustment or replacement. See note
below.
NOTE: If a sensor is not adjustable, further inspection is required to identify and correct
cause.
Attaching hardware threads A Require repair or replacement of hardware.
damaged
Attaching hardware threads A Require repair or replacement of hardware.
stripped (threads missing)
Connector (Weatherpack type) A Require repair or replacement.
leaking
below.
Contaminated A Require repair or replacement. See note
below.
NOTE: Determine source of contamination, such as metal particles or water. Require
repair or replacement.
Inoperative B Require repair or replacement. Further
inspection required. See note below.
NOTE: Inoperative includes intermittent operation or out of OEM specification. Some
components may be serviceable; check for accepted cleaning procedure.
Loose A Require repair or replacement.
Resistance out of specification B Require repair or replacement.
Sensor housing cracked 2 Suggest replacement.
Terminal burned, affecting A Require repair or replacement. See note
performance below.
performance
performance
performance
Home
Terminal loose, affecting B Require repair or replacement.

performance
performance
Wire lead conductors exposed B Require repair or replacement.
Wire lead corroded A Require repair or replacement.
Wire lead misrouted B Require re-routing according to vehicle
manufacturer's specifications.
Wire lead open A Require repair or replacement.
Wire lead shorted A Require repair or replacement.
SPEEDOMETER-DRIVEN GEAR HOUSINGS

See Speedometer/Odometer Drives (Mechanical).
SPEEDOMETER/ODOMETER DRIVES (MECHANICAL)

Speedometer/Odometer Drives (Mechanical)
NOTE: Inoperative includes intermittent operation.
Teeth broken A Require repair or replacement.
SPEEDOMETER/ODOMETER HEADS (MECHANICAL)

Speedometer/Odometer Heads (Mechanical)
Home

Lens broken A Require repair or replacement. See note
below.
NOTE: If lens is available as a separate part, require replacement of lens only.
Lens cloudy 2 Suggest repair or replacement. See note
below.
NOTE: If lens is available as a separate part, suggest replacement of lens only.
Lens missing C Require repair or replacement. See note
below.
Malfunctioning A Require repair or replacement. See note
below.
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out
of OEM specification, or out of range.
SPEEDOMETERS AND ODOMETERS (ELECTRONIC)

Speedometers and Odometers (Electronic)
hardware.
hardware.
below.
Leaking A Require replacement.
Lens broken A Require repair or replacement. See note
below.
Lens cloudy 2 Suggest repair or replacement. See note
below.
NOTE: If lens is available as a separate part, suggest replacement of lens only.
Home
Lens missing C Require repair or replacement. See note

below.
below.
NOTE: Includes inoperative, intermittent operation, failure to perform all functions, out
of OEM specification, or out of range.
Mechanical head noisy 2 Suggest repair or replacement.
below.
performance
performance
performance
performance
SWITCHES
Switches
hardware.
hardware.
Binding, affecting performance A Require repair or replacement.
Binding, not affecting performance 2 Suggest repair or replacement.
Burned, affecting performance A Require repair or replacement. See note
below.
Burned, not affecting performance 2 Suggest repair or replacement. See note
below.
Cracked, affecting performance A Require repair or replacement.
Home
Cracked, not affecting performance 1 Suggest repair or replacement.

below.
NOTE: Includes inoperative, intermittent operation, or failure to perform all functions.
Melted, affecting performance A Require repair or replacement. See note
below.
Melted, not affecting performance 2 Suggest repair or replacement. See note
below.
below.
performance
performance
performance
performance
Won't return A Require repair or replacement.
Worn 1 Suggest replacement.
TONE WHEELS
See Toothed Rings (Tone Wheels).
TOOTHED RINGS (TONE WHEELS)

If the toothed ring requires replacement and cannot be replaced as a separate component, replace the assembly
of which the ring is a part.
Toothed Rings (Tone Wheels)

Alignment incorrect B Require repair or replacement.
Home
Bent B Require replacement.

Contaminated, affecting performance A Require repair. Identify and correct cause.
Cracked B Require replacement.
Loose A Require replacement of worn parts.
Number of teeth incorrect B Require replacement.
Teeth broken A Require replacement.
Teeth damaged, affecting performance A Require replacement.
TORQUE CONVERTERS
Torque Converters
Converter clutch lock-up operation is faulty A Require replacement.
Cover shell damaged, affecting performance A Require replacement.
Does not meet stall speed specification B Require replacement.
End play exceeds specifications B Require replacement.
Hub broken A Require replacement.
Hub cracked A Require replacement.
Internal component failure A Require replacement.
Pilot broken A Require replacement.
Pilot worn, affecting performance A Require replacement.
Weights missing C Require replacement.
TRANSAXLE MOUNTS
TRANSDUCERS (TRANSMISSION)
See Sensors.
TRANSMISSION COOLERS
Transmission Coolers
Air flow obstruction A Require repair.
Home

hardware.
hardware.
Connection leaking A Require repair or replacement.
Contaminated A Require repair or replacement.
Corroded 1 Suggest repair or replacement.
Fins damaged, affecting performance A Require repair or replacement.
Fins damaged, not affecting performance No service suggested or required.
Internal restrictions B Require repair or replacement.
Threads stripped (threads missing) A Require repair or replacement.
Tubes damaged, affecting performance A Require repair or replacement.
Tubes damaged, not affecting No service suggested or required.
performance
TRANSMISSION MOUNTS
TRANSMISSION PANS
Transmission Pans
Bent, interfering with filter or other internal A Require repair or
components replacement.
Leaking A Require repair or
replacement.
TRANSMISSION RANGE INDICATORS (PRNDL)

Transmission Range Indicators (PRNDL)
Components missing C Require replacement of missing components.
Loose, affecting performance A Require repair or replacement.
Out of adjustment A Require repair.
Home
TUBES
UNIVERSAL JOINTS (CARDON OR CROSS TYPE)

Universal Joints (Cardon or Cross Type)
hardware.
hardware.
Bearing cap distorted B Require replacement.
Binding A Require replacement.
Cross (trunion) worn, affecting A Require replacement.
performance
Double cardon centering ball damaged A Require replacement.
Double cardon centering ball worn, A Require replacement.
affecting performance
Double cardon centering spring broken A Require replacement.
Double cardon centering spring missing C Require replacement.
Double cardon centering spring weak A Require replacement.
End cap seal cracked 2 Suggest replacement.
End cap seal missing C Require replacement of seal.
Grease fitting broken A Require replacement of grease fitting.
See note below.
NOTE: A broken grease fitting does not require replacement of the U-Joint.
Grease fitting missing C Require replacement of grease fitting.
See note below.
NOTE: A missing grease fitting does not require replacement of the U-Joint.
Rust-colored powder around end cap seals A Require replacement.
VACUUM CONTROLS
VACUUM HOSES
Home
VACUUM MOTORS
VACUUM-OPERATED SWITCHES
See Switches.
VEHICLE SPEED SENSORS

See Speed Sensors (Electronic Wheel and Vehicle).
VENTS
Vents
Plugged A Require repair or replacement. See note below.
NOTE: A plugged vent may force fluid past the seal.
VIBRATION DAMPERS
Vibration Dampers
Out of position B Require repair or replacement.
WHEEL ATTACHMENT HARDWARE
NOTE: For conditions noted below, also check conditions of wheel stud holes.
CAUTION: Proper lug nut torque is essential. Follow recommended torque

specifications and tightening sequence. DO NOT lubricate threads unless
specified by the vehicle manufacturer.
Wheel Attachment Hardware

Home

Broken A Require replacement. See note below.
NOTE: Some manufacturers require replacement of all studs on that wheel if two or
more studs or nuts on the same wheel are broken or missing.
Loose B Require repair or replacement of affected
component.
Lug nut installed backward B Require repair or replacement.
Lug nut mating surface dished A Require replacement of nut.
Lug nut mating type incorrect B Require replacement of nut.
Lug nut rounded A Require replacement of nut. See note below.
NOTE: Only required if removing wheel.
Lug nut seized A Require replacement of nut. See note below.
NOTE: Only required if removing wheel.
Stud incorrect B Require replacement of stud.
Threads stripped (threads A Require replacement.
missing)
WHEEL SPEED SENSORS

See Speed Sensors (Electronic Wheel and Vehicle).
WIRING HARNESSES AND CONNECTORS

Wiring Harnesses and Connectors
Application incorrect B Require repair or replacement.
hardware.
hardware.
below.
Insulation damaged, conductors exposed A Require repair or replacement.
Insulation damaged, conductors not 1 Suggest replacement.
Home
exposed
Open A Require repair or replacement.
Protective shield (conduit) melted 2 Suggest repair or replacement. See note
below.
Protective shield (conduit) missing 2 Suggest repair or replacement.
Resistance (voltage drop) out of A Require repair or replacement.
specification
Routed incorrectly B Require repair.
Secured incorrectly B Require repair.
Shorted A Require repair or replacement.
below.
Terminal burned, not affecting 1 Suggest repair or replacement. See note
performance below.
Terminal corroded, affecting A Require repair or replacement. See note
performance below.
performance
performance
Transmission connector leaking See Transmission Assembly.
Voltage drop out of specification A Require repair or replacement.
YOKES AND SLIP YOKES

Yokes and Slip Yokes
Bearing cap bore distorted A Require repair or replacement.
Bolt holes elongated A Require repair or replacement.
Bushing or seal surface worn, affecting A Require repair or replacement.
performance
Leaking through soft yoke plug A Require repair or replacement of soft
yoke plug.
Retainer strap bent A Require replacement of retainer strap.
Home
Slip yoke broken A Require replacement.

Splines worn, affecting performance A Require replacement.
Splines worn close to the end of their 1 Suggest replacement.
useful life
U-bolt damaged, affecting performance A Require replacement of U-bolts.
Yoke damaged, affecting performance A Require repair or replacement.
Home

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1998 Chevrolet Pickup C1500

Uniform Inspection and Communication Standards DRIVE TRAIN AND TRANSMISSION

Uniform Inspection and Communication Standards

DRIVE TRAIN AND TRANSMISSION

7101 Wisconsin Avenue

Phone (301) 634-4955 - Fax (202) 318-0378

OVERVIEW OF SERVICE REQUIREMENTS AND SUGGESTIONS

Reasons to Require Repair or Replacement

A - Part no longer performs intended purpose

Reasons to Suggest Repair or Replacement

NOTE: IMPORTANT -When a procedure states that a required or suggested repair or

DRIVE/POWER TRAIN ASSEMBLIES

NOTE: Whenever transmission or drivetrain service is performed that affects the

AUTOMATIC TRANSMISSION/TRANSAXLE ASSEMBLIES

DIFFERENTIAL AND FINAL DRIVE ASSEMBLIES

NOTE: Does not include half shafts.

Differential and Final Drive Assemblies

MANUAL TRANSMISSION/TRANSAXLE ASSEMBLIES

TRANSFER CASE ASSEMBLIES

Transfer Case Assemblies

DRIVE/POWER TRAIN COMPONENTS

Linkage noisy 2 Suggest repair or replacement.

BEARINGS AND RACES

NOTE: When replacing or repacking bearings, grease seal replacement is required.

Bearings and Races

replacement of bearing assembly.

stripped (threads missing) threads if available; otherwise, replace bushing.

Bracket corroded, not affecting 2 Suggest repair or replacement.

CABLES (TV, DETENT, AND SHIFT)

Bracket cracked, affecting performance A Require repair or replacement.

CLUTCH CABLES AND CABLE HOUSINGS

Frayed B Require replacement.

CLUTCH DISCS (MANUAL TRANSMISSION)

Worn close to the end of 1 Suggest replacement.

CLUTCH LINKAGES (MECHANICAL)

CLUTCH MASTER CYLINDERS

CLUTCH PRESSURE PLATES

CLUTCH RELEASE BEARINGS

CLUTCH SLAVE CYLINDERS (CONCENTRIC)

Condition Code Procedure

CLUTCH SLAVE CYLINDERS (CONVENTIONAL OR EXTERNAL)

See Wiring Harnesses and Connectors.

COOLER BYPASS VALVES

Outer covering damaged to the extent that the A Require replacement.

Holes elongated A Require replacement.

DIP STICK TUBES

DIP STICKS (FLUID LEVEL INDICATORS)

DOWEL PINS, GUIDES, AND PILOT HOLES

DRIVE SHAFT FLANGES

DRIVE SHAFTS AND HALF SHAFTS

NOTE: Does not include CV boots.

FILTERS AND SCREENS

See Companion Flanges.

FLUID LEVEL INDICATORS

FLUIDS AND LUBRICANTS

Surface cracks after resurfacing to B Require replacement.

HOSES, LINES, AND TUBES

Outer covering damaged 1 Suggest replacement.

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

INTERMEDIATE SHAFT SUPPORT BEARINGS