Lotus 2004 ELISE Service Notes page 211

Lotus Service Notes
Provision is made for the adjustment of front wheel alignment at the joint between the steering rack track
(tie) rods, and the outer ball joints ('track rod ends'). The required ride height and alignment specification is
detailed in sub-section CI.2.
Track rod end flats
Steering arm
Note that in order to preserve the required bump steer characteristic and steering symmetry, the effective
length of each track rod must remain equal - adjust each track rod by a similar amount:
- Hold the track rod end using the flats provided, and slacken the locknut. Repeat for the opposite side.
- Turn each track rod a similar amount. As a guide, turning both track rods by one quarter of a turn will alter
overall toe-out by approx. 2.0 mm.
- When adjustment is correct, hold each track rod end and tighten the locknuts to 45 Nm (33 lbf.ft).
When slackening or tightening the track rod end locknuts, it is important that the torque reaction is
resisted using the track rod end flats, and that the ball joint itself is not allowed to be stressed.
Track Rod Ends
The track rod ends are sealed for life and maintenance free, but if replacement is required; remove the
ball pin nut and use a ball joint splitter tool to separate the joint from the steering arm. Unscrew the joint from
the track rod. On re-assembly, tighten the ball joint to steering arm nut to 30 Nm, and set the front wheel
alignment as detailed in sub-section CI.2.
Steering Rack Gaiters
The convoluted gaiters sealing each end of the steering rack housing to the track rods, should be in-
spected at service intervals and replaced immediately if found to be torn, cracked or otherwise damaged. The
ingress of dirt or water into the rack housing will cause rapid deterioration of the track rod inner ball joints and
rack and pinion mechanism.
To replace a gaiter, remove the track rod end (see above), release the gaiter clips, and slide the gaiter off
the housing and track rod. Check for consequent damage or wear and replace the steering gear assembly if
necessary. Fit the new gaiter into position, and secure with new retaining clips.
HG.6 - RACK & PINION ASSEMBLY REMOVAL/REPLACEMENT
The rack and pinion assembly is mounted inside an extruded chassis box section crossmember at the top
front of the footwell. Each of the two rack housing mounting plinths uses an M10 (upper) and M8 (lower) fixing
bolt to secure the housing to the vertical rear face of the crossmember. A steel reinforcement channel is
bonded to the outside of the crossmember, with a riveted height setting plate to define the vertical position of
the housing. Note that the only approved repairs or adjustments to the steering rack assembly are the replace-
ment of the track rod ends and rack housing gaiters, and the adjustment of the rack pressure pad.
Page 10
Gaiter
Steering track rod flats
Track rod end locknut
Section HG
c28a