S12 Checklist
Vehicle___________________________
Mileage___________________________
Date______________________________
ITEM	OK	NOT OK	NA	R&R Date	Notes	Action
Tires
1. Drives Side Front Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72ft-lbs
2. Passenger Side Front Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72ft-lbs
3. Drivers Side Rear Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque 58-72 ft-lbs
4. Passenger Side Rear Pressure = 28psi
a. No cracking
b. No uneven wear
c. Clean Rims
d. Tire Protectant inside and out
e. Lug Nut Torque  58-72ft-lbs
5. Spare Tire Inflation OK / Pressure Can Present
6. Spare Tire Condition
7. Spare Tire Lug nuts present
BRAKES
1. Drives Side Front
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.630”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
2. Passenger Side Front
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.630”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
3. Drivers Side Rear
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.350”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
4. Passenger Side Rear
a. Pad thickness greater than 0.079”
b. Rotor Thickness greater than 0.350”
c. Rotor Runout TIR < 0.0028”
d. No cracks in brake hose
e. No leaks
f.  Caliper
5. Brake Lines
a. No leaks
b. No cracks
c. No corrosion
6. Master Cylinder
a. Brake fluid color is clear
b. Change brake fluid DOT3 every 1-2 years
c. Brake Fluid Level
d. No Leaks
7. Proportioning Valve No Leaks
8. Brake Pedal
a. Free Height 7.44”-7.83”
b. Depressed Height 4.33”
9. Emergency Brake
a. Works Freely
b. 8-9 notches
10. Brake Booster
a. No Vacuum leaks
b. No fluid leaks
c. No chafing
CLUTCH
1. Clutch free height
2. Clutch free travel
3. Clutch smooth operation
4. Clutch leaks (master)
5. Clutch leaks (servo)
6. Clutch plumbing leaks, chafing, deterioration
7. Clutch fluid color clear
8. Clutch fluid replace every 2 years
9. Clutch fluid level and air bleed
10. Clutch fork boot no cracks
TRANSMISSION
1. Check for leaks
2. Drain fluid
3. Check magnetic drain plug
4. Check color
5. Refill fluid API GL-4   2.1 liter capacity
6. Check top boot for leaks
7. Check speedometer cable for cracks
8. Replace fluid every 2-4 years depending on conditions
DRIVESHAFT
1. damage check (dents in tube)
2. damage check  (journal wear)
3. looseness check (center bearing)
4. grease leakage
5. tightening torque (center bearing mount)
6. tightening torque (differential)
DIFFERENTIAL
1. Check for leaks
2. Check oil level  (GL-5) 2-3/4 pt 75W-90 cold climate , 140W if above 100 F
3. Check oil color
4. Replace oil every 2-4 years depending on conditions
HALF SHAFTS
1. check for leaks
2. check boots
3. check for loose tripod joints
POWER STEERING
1. check for leaks
2. check fluid color
3. replace fluid every 2-4 years depending on condition
4. check fluid level
5. check lines for chafing
6. check for loose connections
STEERING GEAR
1. check for leaks
2. check boots
3. check for loose fittings
4. check pinion seal
5. check ball joint
6. check dust cover
7. check for missing cotter pins
8. check for grease leakage
9. check steering wheel freeplay < 1.38”
Shocks/Suspension Parts
1. check axle and suspension for looseness
2. Check all bushings for damage
3. retighten all nuts and bolts to specified torque
4. check axle and suspension for wear, cracks, or damage
5. check shock/strut for leakage
6. shock/strut bounce test
Alignment
1. only toe is adjustable
2. camber and castor require aftermarket parts/shims
3. camber –25’ to 1 05’
4. castor 2 45’ to 4 15’
5. kingpin inclination 11 40’ to 13 10’
6. toe in –0.020” to  0.059”
Front wheel bearings
1. check wheel for play
2. check for grease leakage
3. adjust wheel bearing preload if needed
4. replace grease every 2 years
Rear Wheel Bearings
1. check wheel for play
2. replace bearings if play is present
Windshield Glass
1. check for cracks
2. check for crazing, or contamination
3. clean windshield
4. Rain-x inside and out
Lights
1. head lights
2. tail lights
3. clearance lights
4. fog lights
5. step lights
6. door lights
7. dome lights
8. hvac panel lights
9. instrument lights
10. glove box light
11. engine light
12. tail gate light
13. license plate light
Warning Lamps Chime
1. Function is model dependant
Horn
1. check operation
Windshield Washer
1. check front operation
2. check rear operation
3. check fluid level