32 FORD PEDAL ASSEMBLY
HEXPBA02
User Guide & Installation Manual
TECH SUPPORT: 503.693.1918 WWW.HELIXSUSPENSION.COM
The master cylinder is suitable for 4-wheel disc or disc/drum brake setups. The bracket can be bolted or
welded to the left frame rail (boxed or stock).
The selection and installation of brake components should only be done by experienced professionals in the
proper installation and operation of braking systems. The installer must use his/her own discretion to
determine the suitability of the brake components and brake kits for every particular application.
1.) Pick a location that best lines up with a proper brake pedal location. The brake pedal mount can be bolted in or welded in on either
a channeled or a boxed frame rail. This kit is supplied with the correct hardware to bolt it into a channeled frame. If you are using a
boxed frame you will need to supply the correct hardware. Try to keep the master cylinder mounted as level as possible. When selecting
a pedal location you will need to make sure you have enough pedal travel. Make sure the pedal will bottom out the master cylinder
before the pedal touches the floor. Total pedal travel should be about 5 1/2”. The pedal can be bent or modified for driver comfort but
avoid shortening the height of the pedal as this will result in increased pedal effort.
2.) Assemble the master cylinder to the brake pedal frame mount with the 3/8"-16 x 1-1/2" bolts, washers and nylock nuts. Torque
these to 18-24 ft. lbs. Assemble the brake pedal on to the brake pedal frame mount. Install the clevis on to the brake pedal and adjust
the pedal location so the center of the clevis pin is 1/2" forward from the center line of the brake pedal pivot.
3.) The push rod can now be cut to the correct length.
NOTE: REMOVE THE RETAINING CLIP ON THE PUSH ROD WHILE MOCKING UP
YOUR
INSTALLATION. Measure for the correct push rod length and cut it making sure you have a minimum of 1/2" of engagement in
the clevis.
4.) Once you have determined the correct location of the brake bracket, mark and drill the two 1/2" mounting holes in your frame and
bolt it into position with the two 1/2" bolts, washers and nylon lock nuts supplied. Torque these to 38-57 ft. lbs.
5.) Mark the location and angle of the pedal pad and weld the brake pedal pad mount to the brake pedal.
6.) Reinstall the retaining clip on the push rod and install it in the master cylinder piston. With the pedal returned to its non-depressed
position adjust the push rod plunger so there is slight free play between the plunger and the piston on the master cylinder.
7.) The brake pedal should be free to return when no pressure is applied, allowing the master cylinder push-rod to return to its
non-depressed position. Any preload will not allow the hydraulic system to function properly.
In some cases the master cylinder spring (internal) may not be strong enough to fully return the push rod; in this case an additional pedal
return spring can be used. When using an additional return spring the pedal should have an adjustable return stop on it. This will stop
the piston from excessively banging the snap ring located under the rubber boot on the master cylinder. Adjust the stop so the pedal
stops returning at the point when the master cylinder piston retracts against the snap ring.
©2016 The Hoffman Group L.L.C. All rights reserved. HEXPBA02 6/14/2016 Page 1 of 6
The above instructions are for reference only. THG LLC is not responsible for any inaccuracies in the above instructions. THG LLC is also not responsible for any property damage or personal injuries resulting from the
above instructions. Installation by qualified automotive professionals is highly recommended.
1
WARNING
8.) The reservoir closest to the plunger is the front reservoir and gets routed to both front brakes. The rear reservoir is routed to both rear
brakes. If the master cylinder reservoir level is mounted lower that the horizontal plane of the brake calipers a residual check valve will
have to be mounted in line as close to the master cylinder as possible to prevent fluid drain back. A two pound residual check valve is
used for disc brakes and a ten pound is used for drum brakes. An adjustable proportioning valve should be plumed in the rear line to
adjust the front to rear brake bias.
9.) Install the hydraulic brake lines using 3/16" hard lines. Attention must be made to the routing and location of the hydraulic brake
lines. Avoid any heat sources such as exhaust pipes. Install new flex lines making sure you check that the lines have clearance through
the entire suspension travel and turning radius.
10.) Remove the master cylinder and bench bleed it following the attached instructions for bench bleeding. Reinstall the master cylinder,
connect the lines and bleed the entire system per the attached bleeding instructions.
11.) Before operating the vehicle, test the brakes under controlled conditions. Make several stops in a safe area from low speeds,
gradually working up to operating speeds.
12.) Adjust the front to rear brake bias following the instructions supplied with your proportioning valve.
