Lotus Elise Service Notes page 477

Remove the two bolts securing the cylinder to the mounting bracket, and withdraw the cylinder.
To refit, reverse the removal procedure, tightening the slave cylinder mounting bolts to 25 Nm. Clean and
refit the specially coated clevis pin and 'R' pin to connect the pushrod to the release lever and check that the
pushrod is correctly centralised in the slave cylinder piston. Tighten the hydraulic pipe connection to 20
- 24 Nm, and bleed the hydraulic system of air in the usual way. Tighten the bleed nipple to 7 Nm.
To overhaul the slave cylinder:
Clamp the cylinder in a soft jawed vice, and withdraw the pushrod and rubber dust boot from the cylinder.
Withdraw the piston and spring and remove the rubber seal from the piston, taking note of the orientation.
Clean all parts thoroughly with only new brake fluid, and dry with a lint free cloth. Carefully examine the
cylinder bore for scoring, corrosion or visible wear, and replace if any such signs are apparent. If the
cylinder is serviceable, rebuild the unit using new seals and components from the appropriate overhaul
On reassembly, scrupulous cleanliness is essential. Clean hands thoroughly beforehand.
Lubricate the seal, the cylinder bore, and all internal components with clean brake fluid.
Fit the seal into its groove on the piston, with the lip towards the closed end of the cylinder.
Insert the spring and piston assembly into the cylinder, taking care no to bend back the seal lips.
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.
Fit the pushrod throught the dust boot and press the piston against its spring several times to check for
free movement of the piston.
Refit the cylinder as detailed above.
Hydraulic Pipe
The one piece flexible synthetic pipe between master and slave cylinders is routed through the dash
baffle panel and along the outside of the left hand chassis sideframe, enclosed within the composite sill panel,
and wrapped with foam sleeving to supress rattles. In July '98, the pipe specification was upgraded and added
a metal braiding in order better to resist pipe expansion and loss of clutch release travel in conditions of
extreme heat. Service replacement pipes are of only the later type, with the RHD variant supplied with a
separate front end 'U' bend to aid assembly. The pipe should not be withdrawn from the car without attaching
a guide wire with which to aid routing of the new pipe.
kit.
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