Lotus Elise S1 Service Notes page 278

Lotus Service Notes
Section HE
the inside of the new boot.
NOTE: The grease provided in the kits is specially formulated for wear resistance and durability. DO
NOT use substitutes or mix with other lubricants.
9. Inboard Joint: If re-fitting a cleaned out joint, pack the joint with two of the grease sachets from the gaiter
kit. Use the third grease sachet from the gaiter kit to fill the inside of the new gaiter.
10. Slide the outer joint onto the shaft splines, and tap the joint into position until the circlip 'clicks' into its
groove. Pull on the joint to ensure it is fully located.
11. Pull each gaiter over its C.V. joint and locate the lips of the gaiter in the grooves on the joint and shaft.
Before fitting the gaiter clamps, ensure that the gaiter is ventilated so that it is not dimpled or collapsed.
Position the plunging joint with 80 mm between the boot clip grooves before ventilating by inserting a
smooth rod (take care not to damage the boot) between the large end of the boot and the joint, and fitting
the retaining clips. Tighten the clips using suitable pliers.
12. Refit the driveshaft assemblies to the car (see above).
FH.5 - TRANSMISSION REPLACEMENT
With the car supported on a 'wheel free' lift, the transmission can be removed from below, leaving the
engine 'in situ':
1. Remove the LH rear lower wishbone:
- Release the bolt securing the spring/damper unit to the lower wishbone;
- Release the wishbone to chassis pivot bolts;
- Release the parking brake cable clip and swing the wishbone out of the way.
2. Release the RH rear suspension toe control link from the hub carrier, and release the top ball joint plinth
from the hub carrier taking note of the camber adjustment shimplates. in order to allow withdrawal of the
driveshaft from the transmission.
3. Release both driveshaft inboard C.V. joints from the transmission using special wedge tool T000T1276,
or by applying a shock pull to the C.V. joint body using a slide hammer with a forked end. Fit blanking
plug T000T1385 into the transmission to limit the amount of transmission oil loss.
CAUTION: Do NOT attempt to remove an inboard C.V. joint from the transmission by pulling on the
driveshaft. This action will cause the joint to become disassembled and may entail replacement of the
joint. The components of the inboard plunging joint are held in position, for transit purposes only, by a
collar within the boot which will be overidden if excessive axial force is used. Apply pressure only to the
'tulip' or outer body of the joint.
4. Remove the 'R' clip and clevis pin connecting the clutch slave cylinder to the release arm. Remove the
four bolts fixing the slave cylinder bracket to the transmission, and support aside.
5. Release the two bolts securing the starter motor and dirt shield to the clutch housing. Remove the shield,
and withdraw and support the starter motor, taking care to protect the live starter motor lead from ground-
ing.
6. Remove the dirt shield from the top front of the clutch housing.
7. Disconnect the reverse light switch.
8. Disconnect the two gearchange cables from their transmission levers, and release the cables from the
abutment bracket.
9. Remove the air cleaner housing and mounting plate from the roll over bar brace.
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