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HYDRAULIC BLEEDING PROCEDURE 1 GROUP 1 COMPLETE SYSTEM CENTER FEED M C WITH INTEGRAL RESERVOIR CLUTCH TUBE AND SLAVE CYLINDER NOTE System should be bled on the bench before installation into the vehicle 1 1 Remove the S C from the clutch tube by carefully pushing out the C pin with a 3mm punch Retain the C pin Pull the tube from the S C port A seal is used in this position and will either be attached to the connector on the tube or left in the port in the body Remove the seal from the S C port and attach it onto the connector Be sure the seal is present and a seal does not remain in the S C port Be sure the seal is clean and undamaged If the shipping strap is not attached to the S C body attach it by pressing the ends of the arms into the slots in the body flange area 1 2 Fill the S C assembly by holding the S C with the port up and at a 45 angle Pour fluid into the body port until the S C is full and fluid flows out of the body Put the filled S C aside but keep it so the port is up and fluid does not drain out 1 3 Remove the cap and rubber diaphragm from the M C reservoir and place them on a clean dry surface Fill the reservoir with clean brake fluid Allow fluid to freely flow out of the clutch tube until a clear fluid stream is observed Place a finger over the open end of the tube to block the flow Fill the reservoir with fluid and hold the M C with the reservoir end up at a 30 angle allowing air to escape from the M C 1 4 Retrieve the filled S C check the connector on the clutch tube to be sure a seal is on the connector Remove the finger from the connector end of the clutch tube and quickly but carefully plunge the connector into the S C port This must be accomplished before the fluid has drained out of the reservoir Fluid must still cover the hole in the bottom of the reservoir Reinstall the C pin completely into the cross hole in the port This locks the tube in place Pull on the clutch tube while holding the S C to be sure it is firmly attached to the S C 1 5 Check that the reservoir is filled Again tip the reservoir end of the M C up at a 30 angle Gently and slowly push the P Rod into the M C until substantial resistance is felt Repeat this several times Observe the reservoir for air coming out of the M C Continue until no air is seen escaping into the reservoir and until only 2mm of P Rod travel is needed to encounter an increased load 1 6 If the P Rod travels more than 2mm before encountering an increased load do the following 1 6 1 Keeping the M C in the reservoir end in the up position slowly push in the S C P Rod from its restrained position until it bottoms then slowly allowing it to return to its restrained shipping strap in place position 1 6 2 Observe the reservoir for signs of air being expelled Repeat this action two or three times Now repeat step 1 5 above 1 6 3 Check for 2mm of P Rod travel maximum before encountering a heavier load 1 7 If the system passes the 2mm check then check that the S C P Rod strap is in place holding the S C P Rod at its set position and check reservoir fluid level for proper height Install the rubber diaphragm into the reservoir and re install the reservoir cap 1 8 The unit is ready to be installed on the vehicle 2 GROUP 2 REMOTE RESERVOIR CENTER FEED M C TUBE SLAVE CYLINDER SYSTEM NOTE System should be bled on the bench before installation into the vehicle 2 1 Remove the S C from the clutch tube by carefully pushing out the C pin with a 3mm punch Retain the C pin Pull the tube from the S C port A seal is used in this position and will either be attached to the connector on the tube or left in the port in the body Remove the seal from the S C port and put it on the connector on the clutch tube Take care in the following actions not to damage contaminate or lose the seal If the shipping strap is not attached to the S C body attach it by pressing the ends of arms of the strap into the slots in the body flange area 2 2 Fill the S C assembly by holding the S C with the port up at a 45 angle Pour fluid into the body port until the S C is full and fluid flows out of the body Set the S C aside in a vertical position with the port up 2 3 Remove the cap and diaphragm from the reservoir and place them on a clean dry surface Hang the reservoir M C and tube by supporting the reservoir in an appropriate fixture such as a vise Care must be taken not to damage the reservoir Allow the M C and tube to hang downward from the reservoir Holding the M C with the nose up P Rod facing down pour fluid into the reservoir until completely full and allow fluid to freely run out of the connector at the end of the tube Observe the fluid running out of the tube When a clear steady stream is observed seal off the end of the tube with a finger or other appropriate item Be sure the reservoir always has fluid in it sufficient to cover the hole in the bottom of the reservoir Hold the M C so that it is nearly vertical with the P Rod end of the M C pointing down Observe any air coming out of the M C into the reservoir Bubble of air or frothing 2 4 Retrieve the filled S C Check the connector at the end of the tube to be sure the seal is present and undamaged and uncontaminated Remove the finger from the end of the clutch tube and quickly but carefully plunge the clutch tube into the S C This must be accomplished before all the fluid drains out of the reservoir Fluid must still cover the hole at the bottom of the reservoir Re install the C pin completely into the cross hole in the port This locks the tube in place Pull on the clutch tube while holding the S C to be sure the clutch tube is firmly attached to the S C 2 5 Check that the reservoir is filled Again tip the reservoir end of the M C to nearly vertical P Rod end of M C pointed down Gently and slowly push the pushrod into the M C until substantial resistance is felt Repeat this several times Observe the reservoir for air coming out of the M C Continue this action until only 2mm of P Rod travel is needed before feeling the increased load 2 6 If the M C P Rod still travels more than 2mm before encountering the increased load do the following 2 6 1 Keeping the M C in the reservoir end up position slowly push in the S C P Rod from its restrained position shipping strap attached to the S C body until it bottoms 2 6 2 Slowly allow the S C pushrod to return to its restrained position P Rod shipping strap in place and attached to the S C body 2 6 3 Observe the reservoir for signs of air escaping from the M C Repeat this action two or three times Now repeat step 2 5 above 2 6 4 Check for 2mm of P Rod travel maximum before encountering the heavier load 2 7 If the system passes the 2mm check then check that the S C P Rod strap is in place holding the S C P Rod at its set position Check the reservoir fluid level for proper fill height Re install the rubber diaphragm into the reservoir and re install the reservoir cap 2 8 Install the unit into the vehicle 3 GROUP 3 REMOTE RESERVOIR CENTER FEED M C WITH TUBE AND QUICK CONNECT COUPLING NO S C NOTE System should be bled on the bench before installation into the vehicle 3 1 Remove the cap and diaphragm from the reservoir and place them on a clean dry surface Hang the reservoir M C and tube by supporting the reservoir in an appropriate fixture or tool such as a vise Care must be taken not to damage the reservoir Allow the M C and tube to hang down from the reservoir Pour fluid into the reservoir until completely full Hold the M C so that the nose is up at a 45 angle with the pushrod pointed down With a blunt tool depress the small valve in the middle of the quick connect coupling located at the end of the clutch tube Keep the end of the tube and coupling pointed down 3 2 Allow fluid to flow out of the coupling until a steady clear stream is observed Remove the tool and allow the coupling to close Check to be sure the reservoir is at least one half full Check to be sure the O Ring on the outside of the coupling is present clean and undamaged 3 3 Keeping the reservoir end of the M C pointed up slowly depress the P Rod Observe the reservoir for signs of air being expelled from the M C Repeat this until the P Rod can only be pushed 2mm before encountering a substantially higher load If the P Rod load is still very low repeat steps 3 2 and 3 3 until only 2mm of free play remain 3 4 Top up the reservoir with brake fluid Replace the diaphragm and cap onto the reservoir Check to be sure the O Ring on the outside of the coupling is clean and undamaged 3 5 The system is ready to be installed on the vehicle 4 GROUP 5 REMOTE RESERVOIR SEAL OVER PORT LINERED M C WITH TUBE AND S C NOTE System should be bled on the bench before installation into the vehicle 4 1 Remove the C pin from the S C by carefully driving it out with a 3mm punch Retain the C pin Pull the clutch tube and connector out of the S C A seal is used in this position and will either be attached to the connector on the tube or left in the port in the body Check the end of the connector for the presence of a rubber seal If the seal is not on the connector check in the S C port and carefully remove it and place it on the connector 4 2 Hold the S C at a 45 angle and fill the S C by pouring brake fluid into the port until the S C is completely full and fluid flows out of the body Set the S C aside with the port at the top so that fluid does not drain out 4 3 Remove the cap and diaphragm from the reservoir and place them on a clean dry surface Hang the system by supporting the reservoir in a suitable fixture such as a vise Care must be taken not to damage the reservoir Allow the M C and tube to hang down from the reservoir Place a finger over the end of the connector at the end of the clutch tube Holding the clutch tube end of the M C down P Rod end up pour brake fluid into the reservoir until full Remove the finger from the connector allowing fluid to drain out Do not allow the reservoir to completely empty keep at least full When a good solid stream of fluid is noted coming out of the connector replace the finger over the end of the connector blocking the fluid flow Fill the reservoir with fluid until full and watch for air bubbles coming out of the M C 4 4 Retrieve the filled S C Check the connector at the end of the tube to be sure the seal is still there as is clean and undamaged Remove the finger from the end of the clutch tube and quickly but carefully plunge the clutch tube into the S C port This must be accomplished before all the fluid drains out of the reservoir Fluid must still cover the hole in the bottom of the reservoir Re install the C pin completely into the cross hole in the port This locks the tube in place Pull on the clutch tube while holding the S C firmly to be sure the clutch tube is firmly attached to the S C 4 5 Check the reservoir to be sure it is at least to full Tip the nose of the M C down at approximately 45 P Rod end facing up Gently push the P Rod into the M C until substantial resistance is felt Repeat this several times Observe the reservoir for air coming out of the M C Continue this action until no signs of air can be seen coming out of the M C into the reservoir Push on the M C P Rod and there should only be 2mm of movement before feeling a substantially higher load 4 6 If the M C P Rod travels more than 2mm before encountering an increased load do the following 4 6 1 Keeping the M C nose down at a 45 angle slowly push in the S C pushrod inward from its restrained position until it bottoms 4 6 2 Slowly allow the S C P Rod to return to its restrained position P Rod shipping strap in place and attached to the S C body 4 6 3 Observe the reservoir for signs of air escaping from the M C Repeat step 4 5 above 4 6 4 Check for the 2mm of P Rod travel maximum before encountering the heavy load 4 7 If the system passes the 2mm check then check that the S C pushrod strap is in place holding the S C pushrod at its set position Check the reservoir fluid level for proper fill height Re install the rubber diaphragm into the top of the reservoir and re install and tighten the reservoir cap 4 8 Install the unit into the vehicle 5 GROUP 6 DRY ALUMINUM CSC WITH FL EX LINE AND QUICK CONNECT COUPLING NOTE System should be bled on the bench before installation into the vehicle 5 1 Place the CSC into a fixture or a vise that positions the CSC with the bleed tube above the inlet tube and approximately parallel to the floor The nose or bearing end of the CSC should be at a small down angle Care should be taken not to damage the CSC when placing it in a vise 5 2 With the CSC body held in the position described in step a hold the inlet tube and the bleed tube straight up vertical 5 3 Open the bleed screw and leave it open 5 4 Using a blunt tool open the quick connect coupling by pushing down on the plastic valve face in the end of the coupling Care must be taken not to damage this valve area Pour clean brake fluid into the coupling and continue to add brake fluid until a good solid stream of fluid is running out of the bleed screw and no visible signs of air being expelled from the CSC 5 5 Close the bleed screw 5 6 With fluid still being poured into the quick connect coupling release the plastic valve so that it closes Stop adding fluid and pour out excess fluid left on the outside of the plastic valve in the quick connect coupling 5 7 CSC is ready to be installed 6 GROUP 7 EXTERNAL S C WITH TUBE AND QUICK CONNECT COUPLING NOTE System should be bled on the bench before installation into the vehicle 6 1 Remove the clutch tube and coupling from the S C by carefully driving out the C pin with a 3mm punch Pull the tube from the S C port A seal is used in this position and will either be attached to the connector on the tube or left in the port in the body Check to see if the seal is on the end of the connector that came out of the S C body If the seal is not there carefully remove it from the body port and gently push it onto the end of the connector Retain the C pin 6 2 Unhook the shipping strap and allow the S C P Rod to extend until it stops 6 3 Hold the slave cylinder at a 45 angle with the port up and the pushrod facing down Pour clean brake fluid into the S C until completely full and fluid flows out of the body 6 4 Re install the clutch tube into the full S C Install the C pin completely into the cross hole in the port This locks the tube in place Pull on the tube to be sure it is correctly secured in the S C 6 5 Rotate the clutch tube until the quick connect is close to vertical with the S C P Rod hanging down toward the floor Open the plastic valve in the inside at the end of the quick connect coupling with a blunt tool or a clean 10mm diameter long style socket by pushing inward on the plastic valve Care must be taken not to damage this valve area 6 6 With the quick connect valve open push the S C pushrod in until the shipping strap can be hooked to the S C body Do not push any farther fluid should be flowing out of the quick connect coupling 6 7 Hook the shipping strap ears into the areas on the S C body while still restraining the P Rod in position by hand Once the shipping strap is properly attached let go of the P Rod 6 8 Hold the S C horizontal to slightly down and with the tube and quick connect close to straight up With the quick connect valve still held open this can be accomplished by depressing the valve with a clean 10mm diameter long style socket add fluid into the valve until filled to the top Slowly push in the pushrod a few millimeters and release to the constrained position held by the shipping strap Watch for signs of air being pushed out of the S C Repeat this motion also keeping the end of the quick connect full of fluid Repeat until the S C shows no signs of air can be seen being pushed out of the S C Release the plastic valve closing the quick connect 6 9 Push in on the P Rod of the S C There should only be a slight movement before the P Rod stops solid If the S C has a lot 3 or 4mm of movement or more before the P Rod feels solid repeat step h
