Lotus Elise Service Notes page 277

Lotus Service Notes Section HE
Press the C.V. joint into the differential gear splines until a 'click' indicates that the circlip has
engaged in its location. Pull on the body of the joint to check security.
10. Fit the outer end of the shaft into the hub, and retain with the nut.
11. Refit the top ball joint plinth to the hub carrier with the camber adjustment shim pack in position, and
tighten the two socket head bolts to 45 Nm. Apply the parking brake and tighten the driveshaft nut to 220
Nm. Tighten the toe link to hub carrier pivot bolt to 45 Nm. Refit the wheel speed sensor to its plinth.
12. With the car on a level surface, top up the transmission oil to the filler/level plug hole.
Driveshaft C.V. Joint and/or Gaiter Replacement
The outboard joint is available as a separate part, whilst the inboard joint is supplied complete with the
driveshaft. Gaiter kits are separately available for both joints.
1. Remove the driveshaft assembly from the car (see above).
2. Cut off the gaiter retaining clips from both joints, and slide the gaiters along the shaft.
3. The outboard joint is retained by a round section circlip on the end of the shaft. To remove the joint, hold
the drive shaft in a vice, and use a soft mallet to tap the joint over the circlip and off the shaft. If the joint
is reluctant to move, use a brass drift on the front face of the inner race.
CAUTION: Do not attempt to remove an outboard joint without first removing the shaft assembly from
the car. Unless the shaft is securely retained (e.g. in a vise) attempts to remove the outboard joint may
result in the inboard joint becoming disassembled.
4. Slide both C.V. joint gaiters off the driveshaft.
5. Cleaning & Inspection: Complete disassembly of either joint is NOT recommended., The separate
components are a precision fit and develop their own individual wear patterns, such that any interchang-
ing or re-orientation of parts is likely to result in premature failure.
If the grease in the joint is contaminated with dirt or water, it is likely that the joint is damaged, and should
be replaced. If the grease is not contaminated, the joint should be degreased by soaking in a suitable
solvent (NOT petrol), and then carefully inspected.
On the outboard ball type joint, tilt the inner race to one side to expose each ball. Severe pitting, galling,
play between ball and its cage window, any cracking or damage to the cage, or pitting, galling or chips in
raceways, call for joint replacement.
On the inboard, tripod type joint, examine the fit between the rollers and the housing. Excessive free
play, roughness on either roller or track surfaces, damage to the bearings or trunnion, call for joint re-
placement. If the joint is found to be serviceable, it must be repacked with special grease as follows:
Outboard joint; 1 sachet A100R6009 (52 ml) - boot kit contains 2 sachets
Inboard joint; 2 sachet A100R6010 (62 ml) - boot kit contains 3 sachets
6. Replace the circlips securing the inboard joint to the transmission and the outboard joint to the shaft. New
circlips should always be used to ensure security of joint retention. Note that the circlip for the outboard
joint is supplied in the boot kit for either joint, but that the inboard joint circlip should be ordered sepa-
rately.
7 Tape over the shaft outboard splines to prevent damage to the new gaiters, and slide the inboard gaiter
and small retaining clip onto the shaft, followed by the outboard gaiter small clip and gaiter. Remove the
tape.
8. Outboard Joint: New joints are pre-packed with grease, but if re-fitting a cleaned out joint, lubricate the
joint with one sachet of the special grease provided in the boot kit. Fill the ball tracks with grease both
behind and in front of the balls, pack around the balls, and the inside of the splines, so that grease is
pushed behind the joint when the shaft is inserted. Use the second grease sachet from the boot kit to fill
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