Component Assembling; Differential; Synchro Assemblies - Lotus Elise S1 Service Notes

MANUAL GEARBOX
S y n c h r o A s s e m b l i e s
1. Assemble each synchro sleeve to its
respective hub ensuring that raised teeth on
the sleeve are aligned with the deeper grooves
in hub.
2. Fit spring rings to retain hub.
:: Only on® s p r i n g r i n g ss fitted o n 5th
speed s y n c h r o .
3. Assemble synchro rings to their respective
sleeves.
- CAUTION: W h e n a s s e m b l i n g t h e 5th gear
/ | \ s y n c h r o sleeve t o hub, it is p o s s i b l e t o
p o s i t i o n t h e r a i s e d teeth o n t h e s y n c h r o
sleeve in t h e m a c h i n e d cut-aways f o r t h e
s y n c h r o ring. A l t h o u g h the gearbox can b e
assembled, it w i l l not b e p o s s i b l e t o select 5th
gear.
COMPONENT ASSEMBLING
Differential
1. Assemble planet gears and original thrust
washers.
2. Fit sun gears and original thrust washers - if
fitted.
3. Rotate gears and thrust washers to align
drillings in carrier.
~ CAUTION: Do not fit roll p i n or final drive
/ ! \ gear at t h i s stage.
Torsen differential
4. Position speedometer drive gear on carrier.
5. Using a suitable length of tubing, drift gear fully
on to carrier.
Standard differential
*
6. Position speedometer drive gear on carrier.
7. Fit new ball bearings to carrier using tool 18G
1675.
NOTE: Larger of t h e t w o bearings is fitted
on spsedom«tsr drive gear side.
REVISED: 12/97 OVERHAUL
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