Assembly manual - Dual MC kit for Tilton 78 and 79 MC
Assembly of this kit is straightforward and does not require any cutting or filing.
Start by installing the first clevis. Position it so that it sits 1.25 inches from the center of the spherical bearing.
Next, attach the pushrod’s Heim joint to one of the two lever pivot points. The pivot point closer to the balance bar provides a 1.5 ratio (6:1 pedal ratio), while the outer pivot provides a 1.75 ratio (7:1 pedal ratio). It’s a good idea to apply a small amount of grease to the upper pivot on the lever.
Once the rod end is installed on the lever, tighten the M6 Nylock nut that secures the bearing bolt. After tightening, trim or grind off any excess bolt length protruding past the nut.
Apply a light coat of grease to the 1-inch bore where the balance bar will slide, as well as to the 10 mm pivot bolt.
Insert the lever and pushrod assembly into the booster delete housing, feeding the pushrod through the opening toward the firewall. Tighten the M8 Nylock nut, but leave it slightly loose so the lever can pivot freely.
Slide the balance bar into the 1-inch bore in the lever.
Install the second clevis and position it so there is 2.5 inches center-to-center between the two clevises.
Thread in both master cylinders.
Secure the spherical bearings on the master cylinders, making sure to install the 0.5 mm shim between each spherical bearing and its conical seat.
For E90 models, you will need to drill two additional mounting holes in the aluminum brake pedal bracket. The kit includes two bolts already installed—use these as a guide. Mark the locations of the remaining threaded holes and drill accordingly.
Bolt the complete assembly to the firewall.
Finally, connect the clevis to the brake pedal.
Additional model-specific notes:
E30: Reuse the clevis from the factory brake booster
E36: Enlarge the brake pedal hole to 1/2 inch; you may tack weld or leave the stainless steel sleeve loose
E46: Cut the steel wire on the brake pedal
