Lotus 2004 Eleven Service Notes page 115

Lotus Service Notes
DH.5 - TRACK USE CHASSIS REAR BRACE KIT - LOTAC05377
The purpose of the kit is to provide a 'double shear' mounting for the inboard ends of the rear toe-links and
spread the load distribution into the chassis over a wider base. New spherical joints are used on the inboard
ends of the toe-links, with a tubular steel crossbrace interconnecting the two pivot bolts and anchoring to the
rear engine steady mounting on the subframe. For cars used on closed circuits, this arrangement provides an
increased tolerance to abuse. It may be retrofitted on any Elise 111R/'04 Exige/USA Elise (i.e. Toyota power-
train cars).
The rear toe-links comprise the existing outboard taper shank ball joint and toe-link tube, but the inboard
joint is replaced by a new spherical joint with no integral stud. A bespoke spacer locates in the orientation
groove in the (unchanged) subframe and provides a flat surface against which to clamp the pivot ball of the new
joint. A flange head bolt passes through the ball joint and inboard pivot bush of the lower wishbone in a similar
manner to previously, but also locates a brace against the rear 'overhung' end of the ball joint. The tubular
crossbrace on factory built cars prior to December '05, links the two inboard joints via machined adaptor lugs
and turnbuckle adjusters, and is braced directly to the subframe by a welded bracket secured by the engine
rear steady mounting fixings. On later factory built cars using a brace kit, the crossbrace is a simple tubular
link (B120D0040H) without adjusters or subframe bracket. On these cars, a flat washer A120W4199F is used
beneath the head of the crossbrace bolts.
Kit Contents
Tubular Crossbrace, adjustable
Turnbuckle, crossbrace adjustment
Locknut, turnbuckle, M12, RH thread
Locknut, turnbuckle, M12, LH thread
Flange Nut, brace to subframe, M10
Adaptor Lug
Spherical Joint, toe-link inboard
Spacer, spherical joint to subframe
Pivot Bolt, toe link inboad, M10x120x1.25p
Locknut, pivot bolt, M10x1.25p
Fitting Instruction
Procedure (adjustable type crossbrace)
1. Remove the rear undertray and diffuser.
2. At both sides, remove the toe-link inboard/lower wishbone rear pivot fixing nut, release the adjacent heat-
shield fixings and withdraw the ball joint.
3. Cut a vertical slot in the ball joint heatshield at each side, to accommodate the crossbrace adaptor lug,
removing only as much material as necessary.
4. Remove the two rearmost setscrews securing the engine mounting steady bracket to the subframe. If
these screws use weldnuts on the subframe, the nuts must be chiselled or ground off.
5. Fit the locknuts onto the turnbuckles, and screw the LH thread of a turnbuckle into each end of the crossbrace
tube. Fit an adaptor lug onto the RH thread of each turnbuckle. Loosely assemble the crossbrace to the
underside of the subframe plinth using the original setscrews and new flange nuts.
6. On each toe-link, measure the distance from the locknut to the centreline of the inboard pivot ball. Remove
the old joint from the link, and replace with a new spherical joint set to the same approximate position.
7. Fit a new spacer into the orientation slot in the subframe before positioning the toe-link ball joint and sliding
the new pivot bolt through the crossbrace adaptor lug (adjusting the turnbuckle as necessary), ball joint,
spacer, subframe and wishone and retain with a new M10x1.25p locknut. Repeat for the opposite side.
Tighten the pivot bolts only at mid-laden ride height of 130mm to 50 Nm. Re-secure heatshield.
Part Number Qty
A120D0040H 1
A120D0039F 2
A111W3150F 2
A111W3149F 2
A111W3151F 2
A120D0037F 2
A120D0036F 2
A120D0035F 2
A120W2212F 2
A117W3189F 2
LSL489 1
Section DH
Page 11