Rack & Pinion Assembly Removal/Replacement; Track Rod Ends; Steering Rack Gaiters - Lotus Evora Service Notes

Lotus Service Notes
Illustration of track rod adjustment
Note that in order to preserve the required bump steer characteristic and steering symmetry, the effective
length of each track rod must remain equal; compare dimensions and equalise if necessary before subsequently
adjusting each track rod by a similar amount:
- Slacken the rack gaiter outboard clips.
- Hold the track rod using the flats provided, and slacken the locknut. Repeat for the opposite side.
- Turn each track rod a similar amount. As a guide, turning both track rods by one quarter of a turn will alter
overall toe-out by approx. 2.0 mm.
- When adjustment is correct, hold each track rod and tighten the locknuts to 45 Nm. Tighten the rack gaiter
clips.
CAUTION: When slackening or tightening the track rod locknuts, it is important that the torque reaction is re-
sisted using the track rod flats, and that the ball joint itself is not allowed to be stressed.

Track Rod Ends

The track rod end ball joints are sealed for life and maintenance free. If replacement is required;
- Remove the ball pin nut and use a ball joint splitter tool to separate the joint from the steering arm.
- Unscrew the track rod from the steering rack tie rod, using the locknut as a refitment position guide.
- On re-assembly, tighten the ball joint to steering arm nut to 45 Nm, and set the front wheel alignment as
detailed in sub-section CK.2.

Steering Rack Gaiters

The convoluted gaiters sealing each end of the steering rack housing to the tie rods, should be inspected
at service intervals and replaced immediately if found to be torn, cracked or otherwise damaged. The ingress
of dirt or water into the rack housing will cause rapid deterioration of the track rod inner ball joints, rack end
bushes and rack and pinion mechanism, requiring replacement of the complete steering gear.
To replace a gaiter, remove the track rod (see above), release the gaiter clips, and slide the gaiter off the
housing and tie rod. Check for consequent damage or wear and replace the steering gear assembly if neces-
sary. Fit the new gaiter into position, and secure with new retaining clips.
HI.6 - RACK & PINION ASSEMBLY REMOVAL/REPLACEMENT
The steering rack assembly consists of an alloy pinion housing/valve body, and a steel tube through which
the rack is guided. The pinion housing features two solid bushed lugs, which bolt to an extruded alloy bracket,
itself secured to the subframe with four bolts threading into a tapping plate. The non-pinion end is secured by
a 2-bolt clamp and rubber sleeve around the steel tube to a second extruded bracket, secured with two bolts.
Short ball jointed tie-rods from each end of the rack connect, via extended 'track rod ends' to forward facing
steering arms integral with the forged steel front hub carriers.
Note that the only approved repairs or adjustments to the steering rack assembly are the replacement of
the track rod ends, rack housing gaiters, and the pipes connecting the pinion housing to the rack body.
Section HI
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