Lotus 2004 ELISE Service Notes page 194

Lotus Service Notes
Transmission Overhaul Notes
1. Removing and installing 5th and 6th driven gears from the end of the ouput shaft requires considerable
force. The specified puller tools should be used, but when pulling 5th speed driven gear, the claws of the
tool may require some grinding to allow complete and proper fitment, and an anti-spreading device is rec-
ommended to be fitted around the three claws. Striking the puller bolt with a hammer in between tightening
steps will help shock the gear from its interference fit, and engaging two gears to lock the transmission
will also aid the process.
2. The preload on the differential carrier taper roller bearings is controlled by shims between the bearing
outer race and the clutch housing, and is determined by installing the final drive assembly in an otherwise
empty casing, and measuring the steady rotation torque.
3. If the input shaft oil seal is to be replaced, the bearing should also be renewed since this is likely to be
damaged during oil seal removal.
4. The reverse select compression spring shown in the Toyota Repair Manual is not fitted in the Lotus ap-
plication.
5. For cars fitted with a limited slip differential, note the following:
- Apart from the taper roller bearings supporting the differential assembly in the transmission case, the unit
is not serviceable.
- The tightening torque of the bolts securing the final drive gear to the differential assembly = 101 Nm (Std.
diff. = 77 Nm).
- When setting the differential bearing preload (see page 41-28 in Toyota manual D120T0327J) note that a
different procedure must be used due to the construction of the LSD. Instead of fitting only the differential
assembly into the transaxle/transmission case, and then measuring the turning torque directly at the dif-
ferential, LSD versions require that the differential and output shaft be assembled into the casings, and
the turning torque measured by using a torque wrench (27mm socket) on the end of the output shaft.
- Bearing preload (at starting):
New bearings:
Used bearings: 0.11 - 0.22 Nm (1.1 - 2.2 kgf.cm)
- Adjustments are made as for non-LSD.
- There is no special oil requirement for the LSD.
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0.17 - 0.35 Nm (1.7 - 3.6 kgf.cm)
Section FJ
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