D.

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

a.

Wheel Bearings

Inspect front wheel bearings and related

components for condition and proper

adjustment of bearings.

With front wheels

raised (wheels unloaded), grasp tire and

attempt to rock wheel to check for

movement. Spin tire to check for noise and

condition of bearings.

NOTE: It is important to correctly identify

the source of any play.

To determine if

the play is in wheel bearings, have an

assistant fully apply brakes while

rechecking play. If movement disappears

with brakes applied, then play was in

b.

I-Beam

Inspect I-beam axle assembly.

114

 

There is minor seepage of oil or grease

around dust cover (repair).

(Continued on Next Page)

There is dripping of oil or grease around dust

covers.

Dust cover or fasteners are missing or loose.

Any noise, binding, or roughness is

discovered in bearings.

Wheel bearing, end play exceeds

manufacturer’s specifications (maximum of

.010” in and out play measured at bearing

hub).

I-beam has been cut, modified, or is

damaged.

There is any bluing or other evidence that I-

beam has been heated.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

c.

King pins

Inspect king pin assemblies for condition and

play as follows:

1)

?

With front wheels raised, grasp tire at

top and bottom or using a pry bar for

leverage attempt to move the wheel

assembly in and out. (See Figure 11,

page 120.)

NOTE: Wheel bearings must be

adjusted properly (or wheel bearing

play must be eliminated by locking

brakes) before checking king pins.

2)

?

Place a pry bar under wheel and lift

tire straight up and down to

determine condition of thrust bearing.

115

 

Locking pin is loose (repair).

End cap O-rings or bolts are loose or

missing (repair).

(Continued on Next Page)

Locking pin is backing out, or missing.

King pin movement is more than 1/4 inch

measured at outside edge of tire (see Figure

11, page 120).

Vertical (up and down) play in king pin

assembly is greater than .030” (see Figure

12, page 120), and/or thrust bearing is

damaged or missing.

NOTE:

If play is beyond specifications,

wear may be king pin, axle eye, and/or

King pin bushings.

Vehicle should be

grounded if side play at outside edge of

tire is greater than 1/4 inch.

Do not

tighten king pin lock (if equipped) or

grease king pin before inspecting King

pin assembly play.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

d.

Shackles

Inspect condition of shackles, spring

hangers, and pinch bolts.

e.

Spring Mounts

Inspect spring mount bracket(s) for condition

and securement.

Any front spring shackle or hanger is cracked

or broken.

Any front spring shackle or hanger has

significant side wear at spring eye.

Any front spring shackle or hanger is worn, or

pinch bolt is stripped or missing, so that

spring pin cannot be clamped tightly.

Any front spring mount is broken or cracked.

Any front spring mount-to-frame fastener is

loose or missing.

Frame is cracked at any spring mounting

location.

(Continued on Next Page)

116

 

Supp.

 

03-1

 

---

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

f.

Pins and Bushings

Inspect pins and bushings as follows:

Inspect front spring pins and bushings for

wear and lubrication.

Check for wear

with front axle loaded.

Insert pry bar

between spring eye and fixed point at

frame and pull down. Measure total free

play in pins and bushings (see Figure 13,

page 120).

g.

A-Frames and Bushings

Inspect A-frames and bushings for condition

and securement.

117

 

Any spring pin assembly will not accept

lubrication, or zerk (grease) fitting is

damaged or missing (repair).

Rubber bushing(s) are split, badly

deteriorated, or badly extruded from

suspension joints (repair).

(Continued on Next Page)

Total free play (up and down) of pins and

bushings exceeds 1/4 inch (2 pin type) or 1/8

inch (1 pin type). (See Figure 13, page 120.)

Inner sleeve or rubber bushing type spring

pin assembly or assemblies are worn

through, or rubber bushing is excessively

worn (rubber is compacted or deteriorated,

resulting in free play between rubber and

spring eye or inner sleeve).

Rubber bushing(s) are missing.

Any A-frame assembly is bent, damaged,

broken, or any fasteners are loose or

missing.

Any A-frame, bushing, or pivot arm has more

than .050” free play at pivot point.

Mounting of bushing assembly or assemblies

are not secure.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

h.

Ball Joints

Inspect ball joint(s) for condition,

securement, and lubrication.

i.

U-Bolts

Inspect spring U-bolts for condition and

securement.

j.

Shocks

Inspect shocks for condition and

securement.

118

 

Zerk (grease) fitting is missing or damaged,

or ball joint will not take lubrication (repair).

Any U-bolt(s) is misaligned (repair).

(Continued on Next Page)

Any ball joint has more than 3/32-inch axial

play.

Any ball joint nut is loose or missing, or

cotter pin is missing.

Ball joint to A-frame mounting is cracked or

loose, or has been welded.

There is rust underneath U-bolt nuts

indicating possibility of looseness.

Any U-bolt, seating plate, shock mount

bracket, or nut is loose or missing, cracked,

or stripped.

There is wetness around shock body due to

leaking shock fluid.

Any shock mounting or fastener is loose,

missing, cracked, or broken.

Any shock is broken.

Any shock fails to function.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

1.

Inspection Procedures:

Repair (or note) if:

k.

Springs

Inspect front springs for condition,

securement, and alignment.

l.

Wheel Seals

Check for condition and leakage.

119

 

There are any loose, missing, broken or

worn springs clips (repair).

Any coil or leaf spring has flattened, and ride

height is less than manufacturer’s

specifications (repair).

Either front spring saddle (if equipped) is

worn out or missing (repair).

Rubber bumper is missing (repair).

Any leaf spring(s) is broken, cracked, or

missing.

Spring eye is worn or spread such that

bushings are loose in spring eye.

Any coil spring(s) is broken, insecurely

mounted, non-O.E.M. or non-O.E.M. blocks

or spacers are installed.

There is any misalignment of spring leaves

or other evidence that center pin is loose or

broken.

Either front coil or leaf spring is worn so that

rubber frame bumper is damaged or worn

due to frequent bottoming of front

suspension.

Any alignment wedge is loose or damaged.

On any air bag type spring assembly, air bag

is damaged or leaking.

Either front wheel seal is damaged or

leaking.

Supp.

 

03-1

 

---

120

 

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

a.

Brake Hoses

Inspect front brake flexible hoses for

condition, securement, and routing.

b.

Lines

Inspect air and hydraulic brakes lines for

routing, securement, and condition.

121

 

Brake line bracket(s) or securement system

is loose or missing (repair).

(Continued on Next Page)

Any front brake flex hose or connection is

leaking fluid or air pressure.

Any front brake flex hose is kinked,

collapsed, bulging, has damaged plies or

cord, or is damaged below outer covering.

Any front brake flex hose supporting

brackets are damaged or have loose

fasteners.

Any front brake flex hose is rubbing on or

routed against other components.

Any brake line is bent, crimped, or damaged

significantly restricting air pressure or

hydraulic fluid.

Any brake line or connection is leaking air

pressure or hydraulic fluid.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

c.

Chambers

Inspect front brake chamber assembly or

assemblies for securement, condition, and

proper size.

d.

Slacks

Inspect slack adjusters and S-cam

assemblies for wear, condition, operation,

and securement.

NOTE:

See Section D.2.j., page 126 on

brake adjustment for procedure to check

operation of Automatic Slack Adjusters

(ASA).

122

 

Slack adjuster is mounted so that adjuster

bolt is facing chamber (repair).

(Continued on Next Page)

Any brake line is rubbing on other

components or is abraded.

Any brake line is not of O.E.M. material, size,

or type.

Any chamber-mounting bracket is cracked,

bent, or broken.

Any front brake chamber or mounting

fastener is damaged or loose.

Either chamber is not original size, or size of

chambers is not matched left and right (both

sides same size).

Any portion of slack adjuster or S-cam is

missing, broken, cracked, or badly worn.

S-cam shaft and/or S-cam bushing total

wear (up and down) is greater than .040-inch

(see Figure 14, page 127).

S-cam in and out endplay is more than .060-

inch (see Figure 14, page 127).

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

e.

Pushrods

Inspect pushrod assembly or assemblies for

condition, securement, and alignment.

f.

Linings

Inspect linings and foundation brake

hardware for contamination, wear, damage,

and securement.

123

 

Lining wear is extremely uneven left and

right (repair).

(Continued on Next Page)

S-cam snap ring is missing.

Slack adjuster has frozen or stripped worm

gear or ratchet assembly.

Any portion of pushrod assembly (locknut,

pushrod, clevis and pin, or cotter pin) is

loose, missing, or damaged.

Pushrod is rubbing against body of chamber,

or chamber is misaligned.

Pushrods on left and right sides are not

mounted in identical (same) slack adjuster

location hole (same effective slack adjuster

length).

Front brake lining (riveted type shoe) is less

than 3/16-inch thick (Q-type), or ¼ inch (Q­

plus-type), above metal of shoe (shoe table)

at the center of the shoe.

For bonded type linings, front brake lining is

worn to within 1/16 inch of shoe table (face

of shoe).

Front brake lining is worn to within 1/16-inch

of any rivet or bolt head.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

Out of Service if:

Any foundation brake assembly does not

have at least one (1) lining inspection hole.

Lining is broken, cracked, or loose on shoe.

Friction surface is contaminated

grease, or brake fluid.

There is any shimming

lining and shoe.

Lining is not proper size.

material

with oil,

between

Shoe platform or webbing is cracked or

damaged.

There is any loose, damaged, or missing

foundation brake hardware within the drum.

There is any crack (other than heat checks)

in any drum.

There is more than .060-inch wear in drum

friction surface (inside diameter is more than

.120-inch over original).

There is any grease, oil, or brake fluid on

inside of drum.

Supp.

 

03-1

 

g.

Drums

Inspect front brake drum(s) for condition and

oversize.

(Continued on Next Page)

124

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

h.

Rotors

Inspect front brake rotor(s) for mounting,

thickness, and condition.

i.

Wheel Cylinders or Calipers

Inspect wheel cylinder(s) or caliper(s) for

leaks, mounting, and condition.

125

 

Any wheel cylinder or caliper dust boot is

damaged or missing (repair).

(Continued on Next Page)

Drum is not mounted securely to hub, or

fasteners are loose.

Drum is not centered on hub (if equipped)

causing more than .010-inch out of round.

Rotor mounting is not secure.

Rotor has excessive runout (beyond

manufacturer’s specifications) causing a

pulsating in brake pedal.

Rotor has cracks (other than heat checks) or

other mechanical defects.

Friction surface is contaminated with oil,

grease, or brake fluid.

Rotor thickness is less than manufacturer’s

specifications stamped on rotor.

Any rotor friction surface is significantly

grooved or damaged.

Any wheel cylinder or caliper is not securely

mounted or has loose or missing fasteners.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

j.

Adjust Brakes

1)

?

For air wedge brakes or hydraulic

drum brakes, adjust front brakes at

every monthly inspection as follows:

a)

?

Brakes must be adjusted until

brake drum does not turn.

b)

?

Back off brake adjustment until

there is slight drag on drum

surface (.020” clearance between

lining and drum).

2)

?

For S-cam or air disc brakes at every

inspection, brake chamber pushrod

travel must be checked (see Figure

15, page 128) at all four (4) wheel

positions, and brakes must be

adjusted as necessary to achieve

less than or equal to the maximum

pushrod travel (after adjustment)

shown in Chart 13, page 129.

126

 

Any wheel cylinder or caliper is leaking.

There is uneven lining or pad wear, rotor or

drum damage, evidence of dragging, or

other evidence that any wheel cylinder or

caliper may be sticking.

There is any damage or condition, which

prevents proper adjustment of air wedge or

hydraulic drum brakes.

There is any damage or condition, which

prevents proper adjustment of S-cam or air

disc type brakes.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

2.

Inspection Procedures:

Repair (or note) if:

Out of Service if:

3)

?

Automatic Slack Adjusters (ASA)

must be checked as follows:

a)

?

Check pushrod travel before any

adjustment is made.

b)

?

Manually adjust the ASA, if

pushrod travel is beyond stated

limits, before moving bus.

S-cam Bushing Up and Down Play

127

 

Push rod travel exceeds stated limit prior to

adjustment (repair).

Figure 14

Any automatic slack adjuster arm or

mechanism is damaged or loose.

Adjusted stroke (pushrod travel) of any

automatic slack adjuster equipped brake

exceeds maximum shown in Chart 13, page

129.

S-cam In and Out Play

Supp.

 

03-1

 

---

FIGURE 15

PROCEDURE FOR MEASURING PUSH ROD TRAVEL

Brake chamber push rod travel shall not exceed those specifications relating to maximum stroke at which

brakes should be readjusted. Performance of the brake push rod travel inspection should be done with the

brake application air pressure in the range of 80 -

90 p.s.i., when measuring total stroke to determine

proper brake adjustment.

CAUTION:

Chock wheels before commencing this

inspection as vehicle emergency brake(s) must be off.

NOTE: Refer to chart 13, page 129 for Maximum Pushrod Travel

128

 

Supp.

 

03-1

 

---

CHART 13

€

CLAMP TYPE BRAKE CHAMBER

€

(Dimensions in Inches)

€

ROTOCHAMBER

€

AIR DISC BRAKES

€

Type

Maximum

Stroke

Maximum stroke with brakes

adjusted

Maximum stroke at which

Brakes should be adjusted

6

1-5/8

Should

1-1/4

9

1-3/4

be as

1-3/8

12

1-3/4

short as

1-3/8

16

2-1/4

possible

1-3/4

20

2-1/4

without

1-3/4

24

2-1/4

brakes

1-3/4

30

2-1/2

dragging

2

36

3

2-1/4

9

2

Should

1-5/8

12

2

be as

1-5/8

16

2-1/2

short as

2

20

2-1/2

possible

2

24

2-1/2

without

2

30

3

brakes

2-1/2

36

3-1/2

dragging

2-3/4

50

4

3-1/4

12

1-3/8

Should be as

1-3/8

16

1-1/2

short as

1-3/4

20

1-5/8

possible without

1-3/4

24

1-3/4

brakes

1-3/4

30

1-7/8

dragging

2

129

 

Supp.

€

03-1

€

---

D.

UNDERNEATH BUS

3.

Inspection Procedures:

Repair (or note) if:

a.

Engine/Transmission Mounts

Inspect engine and transmission mounts for

condition and securement.

b.

Starter Mounting

Inspect starter for securement and condition.

Check for presence of heat shield

(if equipped).

130

 

Heat shield (if equipped) is loose (repair).

Any mounting fasteners are loose, missing,

or broken.

Any mount is cracked or has deteriorated

rubber.

Any starter mounting bolt, stud, or nut is

loose, damaged, broken, or missing.

Starter is damaged or loose.

Heat shield looseness or damage could

short positive terminal to ground.

Heat shield (if equipped) is missing or

damaged.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

4.

Inspection Procedures:

Repair (or note) if:

a.

Transmission Bolts

Inspect transmission assembly and mounting

fasteners for condition and securement.

b.

Linkage

Inspect transmission linkage for routing,

condition, and securement.

c.

Lines

Inspect transmission lines for securement,

routing, and condition.

131

 

Any transmission assembly fastener(s) is

loose, missing, or damaged (repair).

Modulator (TV) cable or vacuum hose is

routed where it is subject to excessive heat

or abrasion (note).

Any linkage hardware or fasteners are loose

(repair).

Modulator (TV) cable is exposed or casing is

damaged (repair).

Modulator vacuum hose is deteriorated or

loose (repair).

Any transmission line(s) is unsecured or

routed subject to excessive heat or abrasion

(note).

(Continued on Next Page)

Transmission is not mounted securely to

flywheel housing.

There is any external indication that any

torque converter bolt(s) is loose or missing.

Linkage is bent, damaged, binding, or

severely misadjusted.

Any linkage hardware or fasteners are

missing or linkage is damaged so as to

cause a sticking or binding condition.

Modulator vacuum hose is leaking or not

connected.

Any transmission line is crimped.

There is any transmission line of improper

type.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

4.

Inspection Procedures:

Repair (or note) if:

d.

Filter

Inspect transmission external filter assembly

(if equipped) for securement and condition.

e.

Cooler

Inspect transmission cooler (as equipped)

for securement and condition.

f.

Clutch

1.

Operation

a)

?

Check pedal, linkage, clutch, and

throw-out bearing for wear,

slippage, and abnormal noises in

the engaged and released

positions.

132

 

External filter mounting is insecure or has

loose or missing fasteners (repair).

Filter canister is damaged (repair).

Mounting of separate transmission cooler (if

equipped) is insecure or has loose or

missing fasteners (repair).

Loose nuts and bolts (repair).

Noisy throw-out bearing (note).

Clutch out of adjustment (repair).

(Continued on Next Page)

Any transmission line is worn or deteriorated

to the point that failure could occur.

Body of transmission cooler, including all

hose connections, is cracked or damaged.

Cannot adjust clutch to specs.

Excessively noisy throw-out bearing.

Clutch slipping, grabbing, or has excessive

chatter when engaging clutch.

Binding or sticking clutch linkage or return

spring.

Hard to shift transmission.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

4.

Inspection Procedures:

Repair (or note) if:

Out of Service if:

b)

?

Visually check clutch pedal pad

for wear.

c)

?

Check clutch master and slave

cylinders for hydraulic leaks and

operation (if equipped).

2.

Adjustment

Check “free play” travel of the clutch

pedal. This is the first easy

movement of the clutch pedal and

should be no more than 1-1/2-inch

and no less than 3/4- inch of travel.

133

 

Worn pedal cover pad (repair).

Free play is out of adjustment (repair).

Missing pedal cover pad.

Leaking master or slave cylinder or

inoperable.

Clutch slips, grabs, or chatters after

adjusting “free play” travel.

No adjustments can be made.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

5.

Inspection Procedures:

Repair (or note) if:

a.

Oil

Inspect for engine oil leaks at all potential

locations and determine severity.

b.

Coolant

Inspect all potential locations for coolant

leaks.

c.

Transmission

Inspect for transmission fluid leaks at all

potential locations and determine severity.

134

 

Engine oil leakage is causing deterioration of

any rubber parts, such as steering linkage

boots, hoses, etc. (repair).

Engine oil is dripping at any location except

on exhaust system (repair).

There is a drip shield installed to divert oil

from the exhaust system (repair).

There is coolant seepage at radiator, hoses,

heater core, engine oil cooler, thermostat

housing, head gaskets, freeze plugs,

reservoir, water pump, or other potential

locations (repair).

Transmission fluid is causing deterioration of

any rubber parts, such as steering linkage

boots, hoses, etc. (repair).

Transmission fluid is seeping at any location

except on exhaust system (repair).

(Continued on Next Page)

Engine oil is dripping on any portion of

exhaust system.

Leakage is excessive and could result in

imminent engine failure.

Transmission fluid is dripping on any portion

of exhaust system.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

5.

Inspection Procedures:

Repair (or note) if:

d.

Power Steering

Inspect for power steering fluid leaks at all

potential locations and determine severity.

135

 

Power steering fluid is causing deterioration

of any rubber parts, such as steering linkage

boots, hoses, etc. (repair).

Power steering fluid is seeping (repair).

Power steering fluid is dripping.

Power steering reservoir cap or dipstick is

missing

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

6.

Fuel Tank

Inspection Procedures:

Repair (or note) if:

a.

Leaks

€

Inspect fuel tank assembly for leaks.

€

b.

Mounting

Inspect fuel tank mounting system and

barrier (if equipped) for securement and

condition.

There is any fuel leakage from the tank,

connections, or cap, or cap is missing.

The fuel tank has any cracks.

Any connection(s) are loose at the tank.

Any portion of fuel tank mounting system

(including support brackets, retaining straps,

and chassis frame) is missing, loose,

cracked, or broken.

Any fuel tank mounting fasteners are loose

or missing.

Barrier assembly (if originally equipped) is

damaged, insecurely mounted, or missing.

(Continued on Next Page)

136

 

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

6.

Inspection Procedures:

Repair (or note) if:

c.

Hoses

Inspect all fuel lines, hoses, and under-bus

fuel system components, for routing,

securement, and condition.

d.

Wiring

Inspect fuel tank sender unit wiring for

securement, routing, and condition.

137

 

Any wiring or connection has damaged or

missing insulation (repair).

Any fuel line or hose is unsecured or is

routed subject to excessive heat or abrasion.

Any fuel line or hose is deteriorated or

damaged (including cracks or any damage

which may cause potential leakage) or

clamps are loose or missing.

Any under-bus fuel system filter, water

separator, or other components are

insecurely mounted, cracked, or damaged.

Any portion of sending unit wiring (including

ground) or connections is unsecured or is

routed subject to excessive heat or abrasion.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

7.

Inspection Procedures:

Repair (or note) if:

a.

Brake Lines

Inspect all brake hoses, lines, and

connections for routing, securement, and

condition.

NOTE:

External layer weather cracking

b.

Brake Valves

Inspect all brake system valves for

securement and condition.

c.

Reservoir Mounting

Inspect reservoirs (air vacuum tanks) for

securement and condition.

138

 

Any brake hose or line is unsecured (repair).

(Continued on Next Page)

There is any audible air leak or visible

hydraulic brake fluid leakage.

Any brake line or hose is routed subject to

excessive heat or abrasion.

Any brake line or hose is deteriorated or

damaged to the point that failure could occur

(cord frayed, wall thickness thin, rubber

contaminated with oil, crimped, etc.).

Any brake line or hose connection is loose.

There are any audible air leaks or visible

hydraulic fluid leaks from any brake valve.

Any brake valve is not mounted securely, is

cracked, or damaged.

Any reservoir mounting strap or fastener is

cracked, loose, or missing.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

7.

Inspection Procedures:

Repair (or note) if:

d.

Bleed Reservoirs

1)

?

With air system fully charged, check

manual operation of safety relief

valve.

2)

?

Partially open manual petcock valve

on the first (wet) tank.

3)

?

Allow to drain until any moisture

(water) or contamination is drained.

139

 

There is moisture in reservoir (dessicant type

air dryer equipped vehicles only; repair).

Safety relief valve leaks or does not release

pressure.

There is excessive sludge or oil

contamination in the reservoir (more than

eight (8) fluid ounces).

Reservoir leaks due to corrosion or is

cracked.

Supp.

 

03-1

 

---

D.

UNDERNEATH BUS

8.

Inspection Procedures:

Repair (or note) if:

a.

Driveshafts

Inspect driveshafts for condition.

b.

U-Joints

Prior to lubrication, inspect U-joints or

constant velocity (CV) joints (if equipped) for

condition, phasing (alignment of joints),

lubrication, and presence of all hardware.

140

 

Any driveshaft balancing weight (if originally

equipped) is missing (repair).

There is any foreign matter wrapped around

driveshaft (repair).

U-joints or constant velocity joints are dry of

lubrication, or zerk (grease) fitting (if

equipped) is missing, clogged, or

inaccessible (repair).

(Continued on Next Page)

Any driveshaft is bent or seriously dented.

There are any cracks or other damage in

driveshaft, which could cause structural

failure.

There are any missing hardware or fasteners

in any U-joint or CV joint assembly.

Any U-joint has significant cross-shaft-to-

bearing cup play, or CV joint has significant

play.

Any U-joint or CV joint shows evidence of

significant rusting of bearings.

Any bearing cup is loose in yoke.

Supp.

 

03-1

 

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D.

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8.

Inspection Procedures:

Repair (or note) if:

c.

Yokes

Inspect driveshaft yokes for condition and

lubrication.

d.

Hanger Bearings

Inspect hanger bearings and rubber

insulators for condition and securement.

e.

Guards

Inspect for presence and condition of

driveshaft guards.

141

 

Driveshaft splines are unlubricated (repair).

Dust cap on yoke is missing (repair).

Zerk (grease) fitting is missing or clogged

(repair).

Cork washer in dust cap is missing (note).

Hanger bearing rubber insulator is

deteriorated, damaged, or oil soaked (note).

Hanger bearing support is misaligned

(repair).

Any driveshaft guard is bent or damaged

(repair).

(Continued on Next Page)

Any yoke has significant play in splines.

Any yoke is cracked or damaged.

Bearing outer race is loose in insulator, or

inner race is loose on shaft.

There is significant play in hanger bearing.

There is any missing or damaged hardware

or fasteners in hanger bearing or support

assembly.

Any driveshaft guard is missing, or has loose

or damaged mounting fasteners.

Supp.

 

03-1

 

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D.

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8.

Inspection Procedures:

Repair (or note) if:

f.

Driveshaft Park Brake

Inspect driveshaft park brake assembly for

condition, mounting, securement, and

adjustment of linings, drum, linkage, and all

other related hardware.

142

 

Lining is worn down to 2/32-inch from top of

rivet head.

Lining is contaminated with grease or oil.

Lining is broken, cracked, or loose.

Drum is cracked or has excessive heat

damage or scoring of friction surface.

Any actuating or mounting hardware or

fastener is damaged, loose, or missing.

Park brake is not adjusted

manufacturer’s specifications.

per

Supp.

 

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D.

UNDERNEATH BUS

9.

Inspection Procedures:

Repair (or note) if:

a.

Axle Housing

Inspect axle housing for condition and

leakage.

b.

Vent

€

Inspect condition of axle housing vent.

€

c.

Differential

Inspect differential assembly for condition,

lubricant level, and leakage.

143

 

Vent cap is clogged (repair).

Vent hose (if originally equipped) is cracked,

clogged, or missing (repair).

Lubricant level is low (repair).

Differential gaskets or seals are leaking

(repair).

(Continued on Next Page)

Any portion of axle housing is cracked or

bent.

Any portion of axle housing is leaking

lubricant due to cracks, porous metal, or

defective weld.

There is any leakage at or around axle

housing ends.

Axle vent is not functional or is missing.

There is no lubricant in the differential.

Any external differential hardware or

fasteners are loose or missing.

Differential pinion yoke has endplay or

sideplay exceeding manufacturer’s

specifications.

Pinion/yoke end nut is loose or missing.

Supp.

 

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D.

UNDERNEATH BUS

9.

Inspection Procedures:

Repair (or note) if:

d.

Springs

Inspect rear springs for condition,

securement, and alignment.

e.

U-Bolts

Inspect spring U-bolts for condition and

securement.

144

 

There are any loose, missing, broken, or

worn spring clips (note).

Any leaf spring or air suspension ride height

is less than manufacturer’s specifications

(repair).

Rubber frame bumper is missing (repair).

Any U-bolt is misaligned (repair).

(Continued on Next Page)

Any leaf spring is broken or missing.

On any air bag type spring assembly, air bag

is damaged or leaking, or air lines and

valving are damaged or leaking.

Air ride pivot pins and bushings are loose.

There is any misalignment of spring leaves

or other evidence that centering pin is loose

or broken.

Either rear leaf spring is worn to the point

that suspension bottoming has damaged

rubber frame bumper.

There is rust underneath U-bolt nuts

indicating possibility of looseness.

Any U-bolt, U-bolt seating plate, shock

mount bracket, or nut, is loose, missing,

cracked, or stripped.

Supp.

 

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D.

UNDERNEATH BUS

9.

Inspection Procedures:

Repair (or note) if:

f.

Shocks

Inspect rear shocks for condition and

securement.

g.

Shackles

Inspect rear suspension shackles, spring

hangers, and hanger pinch bolts for

condition and securement.

Any shock is broken.

Any shock fails to function.

Any shock mounting or fastener is loose,

missing, cracked, or broken.

There is any wetness around shock body

due to leaking shock fluid.

Any rear spring shackle or hanger is cracked

or broken.

Any rear spring shackle or hanger is worn to

the point, or pinch bolt is stripped or missing,

so that spring pin cannot be clamped tightly.

(Continued on Next Page)

145

 

Supp.

 

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D.

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9.

Inspection Procedures:

Repair (or note) if:

h.

Pins and Bushings

Inspect rear spring pins and bushings for

wear and lubrication.

See Figure 13, page

120, for shackle type system on checking

play in pins and bushings. For other types of

pin and bushing configurations, see

manufacturer’s service manual.

146

 

Any greaseable spring pin assembly will not

accept lubrication, or zerk (grease) fitting is

damaged or missing (repair).

(Continued on Next Page)

Inner sleeve on rubber type spring pin

assemblies is worn through, or rubber

bushing is excessively worn (rubber is

compacted or deteriorated resulting in free

play between rubber and spring eye or inner

sleeve).

Rear spring pin bushing (metal type bushing)

is worn through.

Total free play (up and down) of pin and

bushing exceeds 1/8-inch for single pin type.

On system using two pins and bushings,

combined free play exceeds 1/4-inch.

Supp.

 

03-1

 

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D.

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9.

Inspection Procedures:

Repair (or note) if:

Out of Service if:

i.

Hangers

€

Inspect hangers for mounting and condition.

€

j.

Seals

Inspect rear wheel seals for condition and

leakage.

k.

Wheel Bearings

Inspect rear wheel bearings for condition and

proper adjustment of bearings.

1)

?

Raise rear wheels (wheels unloaded)

and release park brake.

2)

?

Grasp tire and attempt to rock wheel

assembly to check for movement.

147

 

There is wetness or dripping of oil or grease

around axle flange (repair).

Any spring hanger or bracket is cracked or

broken, or any mounting fastener is loose or

missing.

Either rear wheel seal is damaged or leaking

excessively.

Any axle flange stud or nut is loose or

missing.

There is any detectable looseness or

roughness in rear wheel bearings.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

a.

Hoses

Inspect rear brake flexible hoses for

condition, securement, and routing.

b.

Lines

Inspect air and hydraulic brake lines for

routing, securement, and condition.

148

 

Brake line bracket(s) or securement system

is loose or missing (repair).

(Continued on Next Page)

Any rear brake flex hose or connection is

leaking fluid or air pressure.

Any rear brake flex hose is kinked,

collapsed, bulging, has damaged plies or

cord, or is damaged below outer covering.

Any rear brake flex hose supporting brackets

are damaged or have loose fasteners.

Any rear brake flex hose is rubbing on or

routed against other components.

Any brake line is bent, crimped, or damaged

significantly restricting air pressure or

hydraulic fluid.

Any brake line or connection is leaking air

pressure or hydraulic fluid.

Any brake line is rubbing on other

components or is abraded.

Any brake line is not of O.E.M. material, size,

or type.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

c.

Chambers

Inspect rear brake chamber assembly or

assemblies for securement, condition, and

proper size.

d.

Slacks

Inspect slack adjusters and S-cam

assemblies for wear, condition, operation,

and securement.

NOTE:

See Section D.2. j., page 126 on

brake adjustment, for procedure to check

operation of Automatic Slack Adjusters

(ASA).

149

 

Slack adjuster is mounted so that adjuster

bolt is facing chamber (repair).

(Continued on Next Page)

Any chamber-mounting bracket is cracked,

bent, or broken.

Any rear brake chamber or mounting

fastener is damaged or loose.

Either chamber is not original size or size of

chamber is not matched (both sides same

size).

Any portion of slack adjuster or S-cam is

missing, broken, cracked, or badly worn.

S-cam shaft and/or S-cam bushing total

wear (up and down) is greater than .040"

(see figure 14, page 127).

S-cam in and out end play is more than .060-

inch (see figure 14, page 127).

S-cam snap ring is missing.

Slack adjuster has frozen or stripped worm

gear or ratchet assembly.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

e.

Pushrods

Inspect pushrod assembly or assemblies for

condition, securement, and alignment.

Any portion of pushrod assembly (locknut,

pushrod, clevis and pin, or cotter pin) is

loose, missing, or damaged.

Pushrod is rubbing against body of chamber,

or chamber is misaligned.

Pushrods on left and right sides are not

mounted in identical (same) slack adjuster

location holes (same effective slack adjuster

length).

(Continued on Next Page)

150

 

Supp.

 

03-1

 

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D.

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Inspection Procedures:

Repair (or note) if:

f.

Linings

Inspect linings and foundation brake

hardware for contamination, wear, damage,

and securement.

151

 

Lining wear is extremely uneven left and

right (repair).

Rear brake lining is less than 5/16-inch thick

at center of shoe (on brake blocks with

original ¾-inch thickness), (repair).

(Continued on Next Page)

Rear brake lining is less than 1/4-inch thick

at center of shoe (on brake blocks with

original 3/4 -inch thickness).

Rear brake lining is worn to within 1/16-inch

of any rivet or bolt head.

For bonded linings, rear brake lining is worn

to within 1/16-inch of shoe table (at center of

shoe).

Any foundation brake assembly does not

have at least one (1) lining inspection hole.

Lining is broken, cracked, or loose on shoe.

Friction surface is contaminated with oil,

grease, or brake fluid.

There is any shimming material between

lining and shoe.

Lining is not proper size.

Shoe platform or webbing is cracked or

damaged.

There is any loose, damaged, or missing

foundation brake hardware within the drum.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

g.

Drums

Inspect rear brake drum(s) for condition and

oversize.

There is any crack (other than heat checks)

in drum.

There is more than .060-inch wear in drum

friction surface (inside diameter is more than

.120-inch over original).

There is any grease, oil, or brake fluid on

inside of drum.

Drum is not mounted securely to hub, or

fasteners are loose.

Drum is not centered on hub (if equipped)

causing more than .010-inch out of round.

(Continued on Next Page)

152

 

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

h.

Rotors

Inspect rear brake rotor(s) for mounting,

thickness, and condition.

i.

Wheel Cylinders or Calipers

Inspect wheel cylinder(s) or caliper(s) for

leaks, mounting, and condition.

153

 

Any wheel cylinder or caliper dust boot is

damaged or missing (repair).

(Continued on Next Page)

Rotor mounting is not secure.

Rotor has excessive runout (beyond

manufacturer’s specifications) causing a

pulsating in brake pedal.

Rotor has cracks (other than heat checks) or

other mechanical defects.

Friction surface is contaminated with oil,

grease, or brake fluid.

Rotor thickness is less than manufacturer’s

specifications stamped on rotor.

Any rotor friction surface is significantly

grooved or damaged.

Any wheel cylinder or caliper is not securely

mounted or has loose or missing fasteners.

Any wheel cylinder or caliper is leaking.

There is uneven lining or pad wear, rotor or

drum damage, evidence of dragging, or

other evidence that any wheel cylinder or

caliper may be sticking.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

j.

Adjust Brakes

1)

?

For air wedge brakes and hydraulic

drum brakes, adjust rear brakes at

every monthly inspection as follows:

a) Brakes must be adjusted until

brake drum does not turn.

b)

?

Back off brake adjustment until there

is slight drag on drum surface (.020"

clearance between lining and drum.

2)

?

For S-cam and air disc brakes at

every monthly inspection, brake

chamber pushrod travel must be

checked (see figure 15, page 128) at

all four (4) wheel positions.

Brakes

must be adjusted as necessary to

achieve less than or equal to the

maximum pushrod travel (after

adjustment) shown in Chart 13, page

129.

There is any damage or condition, which

prevents proper adjustment of brakes.

There is any damage or condition, which

prevents proper adjustment of brakes.

154

 

Supp.

 

03-1

 

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D.

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Inspection Procedures:

Repair (or note) if:

Out of Service if:

3)

?

Automatic Slack Adjusters (ASA)

must be checked as follows:

a)

?

Check pushrod travel before

any adjustment is made.

b)

?

Manually adjust the ASA if

pushrod travel is beyond stated

limits, before moving bus.

.

155

 

Push rod travel exceeds stated limit prior to

adjustment (repair).

Automatic slack adjuster arm or mechanism

is damaged or loose.

Adjusted stroke (pushrod travel) of any

automatic slack adjuster equipped brake

exceeds maximum shown in Chart 13, page

129 (repair or replace ASA).

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

a.

Body Holddowns

Inspect for securement and condition of all

body holddowns, chassis cowl mounts, and

frame pads. Body holddowns include any J-

bolt, U-bolt, or clamp type holddown used to

secure body to chassis frame.

b.

Floor

Inspect condition of floor structure, sills, and

braces.

156

 

Any body holddown is loose or misaligned,

or there are any cracks or stripped fasteners

at floor sill securement points (repair).

Padding between frame rails and floor sills is

missing or grossly misaligned (repair).

There are any minor cracks in floor sills or

braces or in welds (repair).

(Continued on Next Page)

Any originally installed body holddown or

cowl mount is missing.

Three (3) or more body holddowns are

loose, misaligned, or have missing

hardware.

There are three (3) or more body holddowns

with cracks or stripped nuts at floor sill

securement point.

There are any holes or cracks in floor sheet

metal creating an opening to the passenger

compartment.

Entire cross section of any floor sill or brace

is broken.

There is any broken weld or mounting of a

floor sill or brace resulting in complete

separation more than one (1) foot in length.

There is any broken weld in the mounting of

the bracing (K-member) at the front of the

body floor (between stepwell and driver’s

area).

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

c.

Outriggers

Inspect body outriggers and hardware for

condition and securement.

d.

Braces

Inspect for condition and securement of all

chassis and body braces.

e.

Skirts

Inspect body skirts (and luggage

compartments, if equipped) for securement

and condition.

f.

Frame Rails

Inspect condition of chassis frame rails,

crossmembers, and all hardware attachment

points.

157

 

There is any cracked brace underneath the

body (repair).

Any body skirt, skirt brace, or luggage

compartment has cracked or broken sheet

metal or mounting points (repair).

Luggage compartment door latch, hinge, or

lock is sticking, damaged, or malfunctions

(repair).

Any originally installed (as required by

manufacturer) outrigger is missing.

Any body outrigger is cracked or has loose

or missing hardware.

Any bumper brace is broken, cracked, or

missing.

There is any crack in either frame rail or any

crossmember.

There is any loose or missing rivet or other

fastener securing a crossmember to the

frame.

Supp.

 

03-1

 

---

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

a. Exhaust

Leaks

With engine running and at operating

temperature, inspect exhaust system for

leaks, condition, and securement.

b.

Mounting

Inspect mounting of the exhaust system.

c.

Mufflers

Inspect condition of the muffler.

d.

Tailpipe

Inspect condition of tailpipe and ensure that

it extends beyond the rear bumper and exits

to the left of the left frame rail. (starting

1998, see rear engine type D specifications

for exceptions)

158

 

Any exhaust junction gasket or hardware is

broken or missing (repair).

There is any physical damage to exhaust

system (note).

There is any exhaust system hanger, which

is not securely mounted (repair).

Any exhaust pipe or clamp is loose (repair).

The muffler is cracked (repair).

There is other significant physical damage to

the muffler (note).

The tailpipe is cracked (repair).

There is other significant physical damage to

the tailpipe (note).

There is any leakage, which is audible or can

be felt around any portion of the exhaust

system including manifold(s), pipe sections,

or any junction.

There is any originally installed exhaust

hanger, which is missing, broken, or

detached from exhaust system or frame

mounting point.

Any clamp is missing.

The muffler is leaking.

The tailpipe is leaking.

The tailpipe does not extend at least to the

rear edge of the rear bumper, but not more

than 2-inches beyond bumper or does not

exit to the left of the left frame rail.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

a.

Tread Depth

Inspect and measure all tires for tread depth

and record on inspection form.

Measured tread depth of either front tire is

less than 4/32-inch (2/32-inch for rear tires)

at three (3) points spaced equally around the

circumference of the tire in the same major

tread groove.

Measurement shall not be

taken at a wear bar, and all three (3) points

shall be less than 4/32-inch before tire is

rejected. Measurement shall be taken at the

most worn major tread groove of the tire.

Measured tread depth of either front tire is

2/32-inch or less (1/32-inch for rear tires)

measured at the most worn single point of a

major tread groove, except at a wear bar.

There is evidence that any recapped tire has

been re-grooved.

Any front tire is recapped or re-grooved type

tire.

There is evidence that any tire has been re-

grooved using a procedure not approved by

tire manufacturer or dealer.

(Continued on Next Page)

159

 

Supp.

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

b.

Pressure

With tire cold, check pressures of all tires

and record on inspection form.

NOTE:

Refer to Tire and Rim Association

Manual for correct air pressure for your

specific tire and load rating.

c.

Damage

€

Inspect for damage to wheels and tires.

€

Pressure in any tire is less than the

maximum cold inflation pressure stated on

sidewall of the tire, minus 20%.

Pressure in any tire is greater than 5%

above maximum cold inflation pressure

stated on sidewall of the tire.

There is greater than 20% difference in

pressure between any tires on a particular

axle.

There are any cuts, abrasion, or other

damage to tire sidewall resulting in exposed

or damaged cord.

There is any evidence of separation, bulges

(other than normal manufacturer bulge), or

other damage within the carcass of the tire.

There are any cracks that run around the

bead or sidewall of the tire.

Supp.

 

03-1

 

There is foreign material in the tire tread,

which could cause damage or loss of air

pressure (repair).

NOTE:

Weather cracking only shall not

(Continued on Next Page)

160

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

Out of Service if:

NOTE: Refer to Tire and Rim Association

Manual for correct procedures in

demounting and mounting of tires and

d.

Matching

Inspect for matching of tire construction,

design, size, and load rating on each axle.

161

 

Any valve cap is missing (repair).

There are minor dents or bends in a rim

(repair).

(Continued on Next Page)

On retreaded tire there is any separation of

the tire tread from the tire carcass, which

could result in tire or tread failure.

Any valve stem is damaged or mislocated so

that tire cannot be filled with air.

There is any damage to the lock ring

assembly or lock ring groove of a multi-piece

rim, including rust or corrosion which could

cause the lock ring not to seal fully.

There are any cracks or breaks at the lug

holes or any other part of a rim or cast

spokes.

There are any dents or bends in a rim that

could result in failure of the rim or separation

of the tire from the rim.

There is mismatching of inner and outer dual

tire diameter greater than 3/8-inch.

There is any tire marked for other than

highway use.

Any tire is not of proper type, size, and

minimum load rating.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

e.

Alignment

Inspect tires for evidence of proper

alignment.

f.

Wheel Hardware

Inspect for presence, type, condition, and

securement of all wheel hardware.

Check for proper spacing of rear dual wheels

and tires (proper spacer width).

162

 

Any tire is feather-edged, cupped, or has

uneven tread wear (repair).

Lateral runout of any tire/rim assembly

exceeds 1/4 inch (repair).

(Continued on Next Page)

All tires on an axle are not of same type

(e.g., lug or rib) and size.

Any tire is below minimum load rating.

Radial and bias ply tires are intermixed on

the same axle.

Tires/wheels are grossly misaligned,

affecting steering control.

There is improper matching of rims and lock

rings.

There is evidence of slippage of wheel

assembly on cast spoke hub.

Stud holes are elongated.

Any wheel nut, stud, or clamp is loose, or

there is rust or corrosion indicating possible

looseness.

Supp.

 

03-1

 

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D.

UNDERNEATH BUS

Inspection Procedures:

Repair (or note) if:

Out of Service if:

Inspect for correct wheel color. Stud piloted

and spoke wheels are to be painted black.

Hub piloted wheels are to be painted

National School Bus Yellow.

Inspect for correct wheel type.

163

 

Any wheel, nut, stud, or clamp is broken or

missing.

Any improper spacer is installed between

dual wheels.

Any bus built since October 1987, is not

equipped with disc type (Budd) wheel.

Wheel(s) not painted the correct color.

Stud piloted wheel is installed on a hub

piloted axle or hub.

Supp.

 

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164

 

Supp.

€

03-1

€