Lotus Elise Service Notes page 324

Lotus Service Notes Section JH
2. Before replacing the pads, inspect the caliper for any signs of fluid leakage from a piston seal or joint, and
replace the caliper if any such signs are evident. Clean the pad recess in the caliper taking suitable precau-
tions to protect from dust inhalation.
3. If refitting the existing brake pads, refit each pad in the same position as originally fitted.
4. If fitting new pads, the pistons must be pushed back into the caliper to provide the necessary clearance.
This action will return fluid to the master cylinder such that some fluid may need to be removed in order to
prevent overflowing. Take care to avoid damaging the brake disc surface, or distorting the disc.
5. Position the pads in the caliper, and insert the upper pad retaining pin from the outboard side. Secure with
the split pin.
6. Fit the anti-rattle spring into position with the side tangs pressing against the top end of the pad backplates,
and the centre tang beneath the retaining pin. Insert the second pad retaining pin into the caliper, passing
over the lower central anti-rattle spring tongue.
7. Before driving the car, press the brake pedal several times to bring the pads to their correct running position.
Top up the master cylinder reservoir if necessary to bring the level to the 'MAX' mark.
8. Ensure the customer is made aware that maximum braking efficiency will be achieved if, for the first few
hundred miles, needless heavy braking is avoided, and the brake pads are allowed to 'bed in' fully before
being used to their full potential.
JH.4 - REAR BRAKE PAD REPLACEMENT
Pad thickness may be checked after removing the road wheel, without disturbing the caliper.
Alloy discs Iron discs
Standard pad thickness (excluding backplate); 7.8 mm 6.5 mm
Minimum pad thickness (excluding backplate); 2.5 mm 2.5 mm
If the thickness of any pad is below the specified minimum, the axle set of pads should be renewed. Note
that different brake pads are used for aluminium and iron discs.
Aluminium discs: These pads are identified by a stencilled number on the backplate commencing with 'BXD'. If
desired, self adhesive anti-squeal overlays (A111J0122F) may be fitted to the pads after approx. 0.75mm of wear
has taken place, but some loss of pedal 'feel' will be incurred.
Iron discs: These pads are factory fitted with anti-squeal overlays and marked 'Brembo 07.7236.20.
Pad retaining pin
Tools Required:
Piston Retraction Tool T000T1242
1. Remove the rear road wheels.
2. At each rear corner: using a suitable pin
punch, knock the pad retaining pin out of
the caliper towards the outside, taking
precautions as necessary to restrain the
anti-rattle spring from flying off as the pin
is withdrawn.
3. Remove the anti-rattle spring, and with-
draw both brake pads from the caliper.
Measure the thickness of the lining ma-
terial, and renew the axle set of pads if
any are below 2.5 mm.
Retaining
pin snap
ring
Anti-rattle spring
G H
1998 /
03
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