Lotus 2004 Eleven Service Notes page 220

Lotus Service Notes
Clicking noises, torque reversal 'clonks', or shudder and vibration when accelerating are all possible symp-
toms of worn C.V. joints. It should not be possible to discern any free play in a joint, but care must be taken not
to confuse this with transmission backlash, which will certainly be evident. Any symptoms that could be due to
worn driveshaft joint assemblies, should be investigated and rectified without delay, since a broken driveshaft
can cause considerable damage. Safety considerations should always be accorded the highest priority.
The inboard C.V. joint is equipped with a male splined spigot shaft which engages with the female splines
of the differential output sun gear, with the LH shaft retained by a round section spring circlip on its end, and
the RH shaft retained by the extension shaft support bearing. Each of the two transmission output oil seals
runs on a stepped shoulder on the C.V. joint spigot shaft. The stub shaft of each outboard joint is splined into
the wheel hub, and retained by a nut on the threaded end of the shaft.
Driveshaft Assembly Replacement
Removing a driveshaft assembly from the transmission will result in some loss of transmission lubricant.
It may be preferred to drain off some oil via the transmission drain plug beforehand.
1. Remove transmission drain plug and drain off approx. 1 litre of oil into a clean container for re-use.
2. Remove the rear road wheel.
3. Remove the split pin from the hub nut and remove the nut and washer (right hand thread on both sides).
Before the shaft can be withdrawn from the hub, the top ball joint plinth must be released from the hub
carrier (note camber shims fitted), and the toe-link ball joint separated from the carrier. This will allow the
hub carrier to be pulled away sufficiently for the driveshaft to be withdrawn, but take care not to strain the
brake hose or wheel speed sensor harness.
4. Except C64 RH Driveshaft: The driveshaft inboard joint is retained in the transmission by a round section
circlip. The joint may be removed by applying a shock pull to the C.V. joint body using a slide hammer
with a forked end.
CAUTION: Do NOT attempt to remove the inboard C.V. joint from the transmission by pulling on the
driveshaft. The balls of the inboard joint are restrained for transit purposes only, by a circlip at the end of
the ball tracks. Applying an extension force to the joint will damage the balls and require joint replacement.
Apply pressure only to the outer body of the joint.
C64 RH Driveshaft: This driveshaft incorporates a bearing for the extension shaft and it is this which
retains the shaft in the transmission. Remove the two bolts securing the bearing bracket, and withdraw
the complete shaft assembly.
When withdrawing either driveshaft from the transmission, take care not to damage the output oil seal.
6. Before re-fitting a driveshaft, first renew the round section circlip on the end of the inboard joint spigot shaft,
and lubricate the circlip with grease. Also, check the condition of the transmission output seal, and renew
if necessary. Lubricate the lip of the seal with transmission oil, and grease the corresponding shoulder
on the driveshaft (C.V. joint) spigot, to reduce the danger of damaging the seal on assembly.
7. Carefully insert the driveshaft into the transmission, with the two ends of the circlip positioned lowermost,
and rotate the shaft if necessary to engage the splines. Press the inboard joint outer until a click indicates
the engagement of the retaining circlip, if necessary using a brass drift and hammer. Afterwards, pull on
the joint body to check its security. On the C64 right hand shaft, fit the bolts securing the extension shaft
bearing to the engine mounted bracket, and torque to 64 Nm.
8. Fit the outer end of the shaft into the hub, and refit the top ball joint plinth to the hub carrier with the cam-
ber adjustment shim pack in position. Apply Permabond A130 (A912E7033V) to the threads of the two
socket head bolts and torque to 45 Nm.
9. Refit the toe-link into the hub carrier and torque the retaining nut to 55 Nm.
10. Fit the washer and castellated nut to the driveshaft, apply the parking brake and tighten the nut to 220
Nm. Fit a new split pin to lock the nut.
11. With the car on a level surface, top up the transmission oil to the filler/level plug hole.
Section FJ
Page 15