Assembly of that kit is very simple and requires no cutting or filing.
Start by fitting the first clevis, making sure it is 1.25” from the spherical bearing’s center.
Fit the push rod’s Helm joint into the one of the two lever pivot. Closer to the balance bar is a 1.5 multiplier (6:1 pedal ratio), the one further is 1.75 multiplier (7:1 pedal ratio). A bit of grease in the lever’s upper pivot is a good idea.
After fiting the rod end on the lever, once the M6 Nylock securing the bearing bolt on the lever is fastened, then cut/grind the excess bit that portrudes from the nut.
Slightly grease/lube the 1” bore where the balance bar will slide as well as the Ø10mm pivot bolt.
Place the lever/push rod assembly into the booster delete’s body after sliding the pushrod thru the opening toward the firewall. Tighten the M8 Nylock, but still let a bit of loose so that the lever can pivot.
Insert the balance bar into the lever’s Ø1” bore
Fit the second clevis and position it 2.5” center to center from the other clevis.
Screw in the two MCs
Bolt the MCs spherical bearings and do not forget the 0.5mm shim between the spherical bearing and the conical mount.
If you have an e90, then you must add two mounting holes on the aluminum brake tower. The kit is supplied with only two bolt fitted. Use it as a guide while the empty threaded hole are where you must make a mark and drill.
Bolt the complete assembly to the firewall
On the e30, you must reuse the clevis from the brake booster. On the e36, the hole on the brake pedal must be enlarged to Ø1/2” and you can tack weld or let loose the stainless steel sleeve. On the e46, you must cut the steel wire on the brake pedal
Connect the clevis unto the brake pedal
Assembly of that kit is very simple and requires no cutting or filing.
Start by fitting the first clevis, making sure it is 1.25” from the spherical bearing’s center.
Fit the push rod’s Helm joint into the one of the two lever pivot. Closer to the balance bar is a 1.5 multiplier (6:1 pedal ratio), the one further is 1.75 multiplier (7:1 pedal ratio). A bit of grease in the lever’s upper pivot is a good idea.
After fiting the rod end on the lever, once the M6 Nylock securing the bearing bolt on the lever is fastened, then cut/grind the excess bit that portrudes from the nut.
Slightly grease/lube the 1” bore where the balance bar will slide as well as the Ø10mm pivot bolt.
Place the lever/push rod assembly into the booster delete’s body after sliding the pushrod thru the opening toward the firewall. Tighten the M8 Nylock, but still let a bit of loose so that the lever can pivot.
Insert the balance bar into the lever’s Ø1” bore
Fit the second clevis and position it 2.5” center to center from the other clevis.
Screw in the two MCs
Bolt the MCs spherical bearings and do not forget the 0.5mm shim between the spherical bearing and the conical mount.
If you have an e90, then you must add two mounting holes on the aluminum brake tower. The kit is supplied with only two bolt fitted. Use it as a guide while the empty threaded hole are where you must make a mark and drill.
Bolt the complete assembly to the firewall
On the e30, you must reuse the clevis from the brake booster. On the e36, the hole on the brake pedal must be enlarged to Ø1/2” and you can tack weld or let loose the stainless steel sleeve. On the e46, you must cut the steel wire on the brake pedal
Connect the clevis unto the brake pedal