Lotus Elise S1 Service Notes page 317

To remove the intermediate column assembly, the upper column must first be removed (see sub-section
HE.3), after which the rack pinion shaft pinch bolt may be removed and the column assembly withdrawn.
Match marking the lower u/j to the pinion shaft will aid steering wheel alignment on re-assembly. Torque
tighten the pinch bolts to 35 Nm.
HE.5 - TRACK ROD ENDS & RACK GAITERS
Front Wheel Alignment
Alignment is measured either by the angle a wheel makes with the vehicle centre line, or the difference in
dimension between the wheel rim to wheel rim measurement at the front and rear of the wheel at hub centre
height. The wheels are said to 'toe-in' when the wheel paths converge ahead of the vehicle, and 'toe-out' when
they diverge. Wheel alignment is designed to vary with both steering angle (Ackerman) and suspension travel
(bump steer) and should be measured only 'straight ahead' at the specified ride height.
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 CG.2.
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 80 - 82 Nm (58 - 60 Ibf.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 CG.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
GUI
Page 317