Wilwood 60 Degree Pedal Description - Manual (Page 4)

Page 4
-•To determine the proper pushrod length adjustment, depress the brake pedal through a full range of travel to observe the angle change
that occurs in the balance bar and note the difference in stroke lengths between the two master cylinders. Once the master cylinder
with the longer stroke requirement has been identified, adjust that pushrod to a longer length that is equal to approximately 1/2 of the
total amount of the stroke difference. For example, if one master cylinder has a 1/2” longer stroke requirement than the other, adjust
that pushrod to a length that is approximately 1/4” longer. Continue the process until a length setting is achieved that allows the balance
bar to be square and perpendicular to the pushrods when the pedal has been depressed to approximately 1/2 of its full travel. This
should represent a position that is achieved during a medium stop. The balance bar should then travel over square during a high effort
hard stop. The angle change in the balance bar before and after center should be equal. Adjusting the pushrods to compensate for this
balance bar angle change through the full range of pedal effort is necessary to prevent bind in the bearing, interference between the
bar and the pivot body, ineffective bias control, and potential damage to the balance bar assembly itself.
Figure 3. Push Rod Length Adjustment
TOP M/C
BOTTOM M/C
TOP M/C
BOTTOM M/C
TOP M/C
BOTTOM M/C
NO PEDAL EFFORT
NOTE:
THE PUSHROD ADJUSTMENT DEPICTED IN THIS FIGURE IS REPRESENTATIVE OF ANY APPLICATION WHERE THE TOP MASTER CYLINDER
HAS THE LONGER STROKE REQUIREMENT. ON A N.E. DIRT MODIFIED, THIS WOULD REPRESENT THE REAR MASTER CYLINDER ON TOP.
IF THE LONGER STROKE MASTER CYLINDER IS ON THE BOTTOM, SET THE PUSHROD LENGTHS ACCORDINGLY WITH THE LONGER
PUSHROD LENGTH ALWAYS GOING TO THE MASTER CYLINDER WITH THE LONGER STROKE REQUIREMENT.
MODERATE PEDAL EFFORT HEAVY PEDAL EFFORT
Figure 4. Balance Bar Lever Interference
INTERNAL BORE
OF PEDAL HOUSING PEDAL HOUSING
WASHER
CLEVIS
INCORRECT ADJUSTMENT:
LEVER (BOLT) SHOULD NOT
BIND ON PEDAL HOUSING
BORE THROUGH ENTIRE
PEDAL TRAVEL
General Pushrod Length Adjustment Procedures
•Once the system has been fully bled, stabilized, and checked for leaks, the master cylinder pushrod lengths must be adjusted for proper
travel and pivoting of the balance bar assembly
•If all four brake calipers have the same number of pistons of the same size, and both master cylinders have the same bore diameter,
adjust the master cylinder pushrods to equal lengths and set the jam nuts against the clevis to lock the pushrods in place.
• For vehicles with different caliper or master cylinder sizes between front and rear, the pushrod lengths must be adjusted to compensate
for the difference in master cylinder stroke lengths that occur when using differently sized components within the system. These
pushrod length adjustments are necessary to prevent bind in the balance bar bearing that could otherwise be caused by excessive
misalignment angle in the bar. See Figure 3.