Component Assembling; Differential; Synchro Assemblies - Lotus Elise Service Notes

MANUAL GEARBOX
Synchro Assemblies
1. Assemble each synchro sleeve to its
respective hub ensuring that raised teeth on
the sleeve are aligned with the deeper grooves
in hub.
2. Fit spring rings to retain hub.
NOTE: Only on® spring ring ss fitted on 5th
speed synchro.
3. Assemble synchro rings to their respective
sleeves.
- CAUTION: When assembling the 5th gear
/ | \ synchro sleeve to hub, it is possible to
position the raised teeth on the synchro
sleeve in the machined cut-aways for the
synchro ring. Although the gearbox can be
assembled, it will not be possible to select 5th
gear.
COMPONENT ASSEMBLING
Differential
1. Assemble planet gears and original thrust
washers.
2. Fit sun gears and original thrust washers - if
fitted.
3. Rotate gears and thrust washers to align
drillings in carrier.
~ CAUTION: Do not fit roll pin or final drive
/ ! \ gear at this stage.
Torsen differential
4. Position speedometer drive gear on carrier.
5. Using a suitable length of tubing, drift gear fully
on to carrier.
Standard differential
*
37M1143
6. Position speedometer drive gear on carrier.
7. Fit new ball bearings to carrier using tool 18G
1675.
NOTE: Larger of the two bearings is fitted
on spsedom«tsr drive gear side.
REVISED: 12/97 OVERHAUL
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