Lotus Elise Service Notes page 476

Lotus Service Notes Section QF
On reassembly, scrupulous cleanliness is essential. Clean hands thoroughly beforehand.
Lubricate all seals, the cylinder bore, and all internal components with clean brake fluid.
Fit the secondary seal into its groove on the piston, with the lip towards the front.
Fit the piston washer, primary seal and spring retainer onto the front end of the piston, with the lip of the
seal facing forwards.
Insert the spring and piston assembly into the cylinder, taking care no to bend back the seal lips. Fit the
stop washer and retain by fitting the circlip into the groove in the rear end of the cylinder bore. Check that
the circlip is seated correctly in the groove. Pack the inside of the dust boot with rubber grease and seat
the lip of the boot in the groove on the outside of the cylinder body.
Use a suitable rod to operate the piston by hand several times to check for free movement of the internal
parts.
Refit the cylinder as detailed above.
Slave Cylinder
The slave cylinder is secured by two bolts to a mounting bracket on the transmission, and is connected to
the clutch operating lever by a fixed length pushrod and clevis pin. A sleeve nut is used to connect the flexible
hydraulic pipe, and a bleed nipple is provided by which to bleed air from the hydraulic system.
Bleed nipple
Clutch slave
cylinder
Mounting
bracket
Operating
lever
Pushrod
Flexible pipe
Eg
To replace the slave cylinder:
Clean the slave cylinder and surrounding area with methylated spirit. Do not use petrol or paraffin.
Take all necessary precautions to guard against contamination of painted surfaces with brake fluid.
Remove the 'R' pin and clevis pin connecting the pushrod to the clutch operating lever.
Disconnect and immediately plug and cap the hydraulic hose connection.
Page 6
1998 / 02