200 SERIES LUTV BRAKE BLEEDING INSTRUCTIONS
NOTE: This procedure requires 2 individuals to complete
TOOLS REQUIRED
Page 1 of 2 8mm Wrench
12mm Wrench
IMPORTANT: Check and maintain adequate levels of DOT3 brake fluid in the
master cylinder at all times during this procedure.
DO NOT LET IT RUN DRY PREPARATION
1 LOCATE AND REMOVE COTTER PIN (fig. 1 & 2)
Brake T Block • Straighten and remove the cotter pin located on the brake block pin. Remove brake
Cotter Pin block pin holding the T block on to the brake pedal assembly.
2 REMOVE ONE PUSH ROD FROM T BLOCK (fig. 3)
• Using a 12mm wrench loosen the jam nut and remove one of the brake adjust push
rods.
Brake Block Pin 3 REPLACE BRAKE T BLOCK (fig. 4 & 5)
• Replace the brake T block for bleeding either the front brakes (flip the T block so that
Brake Block Pin the push rod is on the left / driver side) or bleeding the rear brakes (push rod on the
Brake Pedal right / passenger side) and replace the brake block pin (no need to re-install the cotter
Fig. 1 Fig. 2 pin at this time). NOTE: Fig. 4 shows T block being replaced for rear brake
bleeding.
Brake Adjust Push Rod 4 LOCATE AND REMOVE BLEEDER VALVE CAP (fig. 6 & 7)
Brake T Block • Have your assistant locate the applicable bleeder valve (rear brakes located between
the rear passenger wheel and the engine / front brakes located on the inside of each
front wheel).
NOTE: When bleeding front brakes, it is best to bleed passenger side first.
BLEED PROCEDURE (continued on page 2)
5 PUMP AND HOLD BRAKES (fig. 9 & 10 on page 2)
Jam nut
Note: Procedure is the same for both front & rear brakes
• Make sure that the master cylinder is full with DOT3 brake fluid. Pump the brake
Fig. 3 Fig. 4
pedal 3 to 4 times and hold it down. While held in place, have assistant loosen the
bleeder valve with an 8mm wrench and check if air or fluid comes out. Have assistant
close valve and then release brake pedal. Repeat as necessary until only a steady
Bleeder Valve Cap stream of brake fluid comes out of the bleeder valve. Have assistant close the bleeder
FRONT OF VEHICLE
valve and release pedal. The brake is now fully bled.
PASSENGER SIDE REAR TIRE
ENGINE
Brake Block Pin
Fig. 5 Fig. 6
Bleeder Valve Cap
Bleeder Valve
FRONT OF VEHICLE
PASSENGER SIDE REAR TIRE
ENGINE
FRONT
PASSENGER
Fig. 7 TIRE Fig. 8 Fig. 9
200 SERIES LUTV BRAKE BLEEDING INSTRUCTIONS
NOTE: This procedure requires 2 individuals to complete
Page 2 of 2
IMPORTANT: Check and maintain adequate levels of DOT3 brake fluid in the
master cylinder at all times during this procedure.
DO NOT LET IT RUN DRY BLEED PROCEDURE (continued)
6 SWITCH PUSH ROD (fig. 11)
Brake Adjust Push Rod • Following steps 1 through 3, flip the brake T block to bleed the other brake system.
Bleeder Valve (Figure 11 shows preparation for bleeding the front brakes.)
NOTE: When bleeding front brakes, it is best to bleed passenger side first.
7 BLEED REST OF BRAKES
• Repeat the bleeding procedure for any remaining brakes. There should be one valve
to bleed for the rear brakes and 2 valves to bleed for the front.
NOTE: Remember to monitor the fluid level of the master cylinder throughout the
bleeding process.
8mm Wrench
Fig. 10 Fig. 11
REASSEMBLY
8 REPLACE PUSH ROD INTO T BLOCK (fig. 12, 13 & 14)
• Replace removed brake push rod back into the brake T block and tighten with a
12mm wrench. Install the brake T block with both pushrods back into the brake pedal
assembly and reinsert brake block pin. Replace cotter pin as it was before bleeding.
Fig. 12
Brake Block Pin
Fig. 13
Cotter Pin
4404 Engle Ridge Drive
Fort Wayne IN 46804
62194 Commercial Street
Roseland, LA 70456
Toll Free 800-643-7332
Fax 866-329-5278
Fig. 14 www.amsportworks.com
