Lotus 2004 ELISE Service Notes page 225

Lotus Service Notes
- Unscrew the gear lever knob.
- Release the fixing screw at either side of the gear lever shroud base.
- Remove the single screw retaining the rear bulkhead centre pocket, and then the two screws securing the
rear shroud. Disconnect the auxiliary power socket.
- Lift the centre trim panel, label and disconnect the CDL switch and (if fitted) hazard switch, and release
the gear lever gaiter.
Note that the parking brake/gearchange lever mounting bracket is not drive handed, but is offset, via
alternative fixing holes in the chassis, towards the passenger side. The ratchet pawl operates a micro switch
to light the 'brakes' tell tale lamp in the instrument panel whenever the ignition is switched on and the parking
brake is applied. The short front cable is connected to the lever assembly by a clevis pin with spring retaining
clip. When carrying out any work in this area, take care not to damage or misroute the electrical main harness.
JJ.7 - BRAKE DISCS
All four wheel brakes use a brake disc which is sandwiched between the wheel and its hub flange, being
centralised by the hub spigot, and transmitting torque via the clamping force of the road wheel bolts. A
countersunk screw is used to retain the discs for convenience when servicing.
The same disc is used at each corner of the car, and features cast iron construction with internal curved
vane cooling and cross-drilling. The opposite direction of rotation of the curved vanes on each side of the car
does not significantly affect the cooling performance of the disc. The condition of the brake disc friction
surface is a major factor in brake performance and feel, with a good surface quality and minimal run-out and
thickness variation being required. After an extended lay up, some surface corrosion may develop on the discs
which will cause a degradation in braking quality until the surfaces are cleaned up by normal brake action.
Excessive run-out or thickness variation as a result of overheating or extended wear, may cause brake judder
and/or extended pedal travel due to pad 'knock off'. Scoring and ridging of the braking surfaces will be exac-
erbated by operation in dusty or unmetalled road environments, and will reduce braking performance.
No skimming or re-surfacing of the brake discs is recommended. If the disc becomes badly scored, or is
out of specification in any way, it should be renewed. NOTE: Ensure that there is no discernible free play in the
wheel bearings before attempting to measure brake disc run-out. If disc run-out exceeds the service maximum,
check the hub run-out before replacing the disc.
Brake disc thickness:
Runout:
Hub:
Front Disc Replacement
1. Remove the road wheel.
2. Remove the two bolts securing the brake calliper to the hub carrier, and withdraw the calliper from the
disc. Secure clear without straining the flexible hose.
3. Remove the single countersunk screw, and withdraw the disc from the hub.
4. Before re-fitting a disc, ensure that the mating face between disc and hub is scrupulously clean. Mount
the disc onto the hub and align the wheel bolt holes.
5. Apply Permabond A130 (Blue - A912E7033) to the threads of the calliper fixing bolts. Fit the calliper over
the disc and secure to the hub carrier with the two bolts. Tighten to 45 Nm (33 lbf.ft).
6. Refit the road wheel and operate the brakes before driving the car to set the brake pad position.
Rear Disc Replacement
Replacement of the rear discs is similar to that for the front discs, except that if the brake pads are
removed, it is not necessary to remove the brake calliper to enable the disc to be withdrawn from the hub.
New
Service minimum
New maximum
Service maximum
Disc mounting face run-out max.
Section JJ
26.0 mm (1.02 in)
24.0 mm (0.98 in)
0.03 mm (0.001 in)
0.10 mm (0.004 in)
0.04 mm (0.0015 in)
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