Lotus 2004 Eleven Service Notes page 221

Lotus Service Notes
Driveshaft C.V. Joint and/or Gaiter Replacement
The outboard C.V. joint is supplied complete with main driveshaft to which it is fixed by a spline with a small
helix angle to eliminate any potential backlash. Separation of the shaft from the joint should not be attempted.
Note that the RH main shaft is 22mm longer than the LH shaft. Replacement of the outboard joint gaiter entails
removal of the complete driveshaft assembly from the car, and removal of the inboard joint from the shaft.
1. Remove the driveshaft assembly from the car (see above).
2. Remove the clips securing the inboard joint gaiter without damaging the gaiter if it is to be re-used. Pull
the gaiter off the joint outer body, remove the circlip in the end of the joint outer body and match mark the
body to the joint inner race before sliding the body off the shaft assembly.
3. Remove the circlip from the end of the shaft and match mark the inboard joint inner race to the shaft before
pulling or pressing the race from the shaft. Slide the inboard gaiter off the shaft.
4. Remove the clips securing the outboard gaiter, and slide the gaiter off the shaft.
5. Inspection & Cleaning: Complete disassembly of either joint is NOT recommended. The separate com-
ponents are a precision fit and develop their own individual wear patterns, such that any interchanging or
re-orientation of parts is likely to result in premature failure.
If the grease in the joint is contaminated with dirt or water, it is likely that the joint is damaged, and should
be replaced. If the grease is not contaminated, the joint should be degreased by soaking in a suitable
solvent (NOT petrol), and then carefully inspected. Tilt the inner race to one side to expose each ball.
Severe pitting, galling, play between ball and its cage window, any cracking or damage to the cage, or
pitting, galling or chips in raceways, call for joint replacement.
If the joint is found to be serviceable, it must be repacked with the special grease provided. Pack the
grease into the joint itself and also into the inside of the new gaiter.
NOTE: The grease provided in the kits is specially formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants. The grease specification and quantity also differs for inboard
and outboard joints:
Inboard: 140g NKG 205
Outboard: 130g NTG 2218M 99-729#BJ100 (inboard grease is also supplied as the inboard joint must
be removed before fitting outboard gaiter)
6. Slide the new outboard gaiter and smaller retaining clip onto the shaft. Fit the gaiter into the grooves on
the outboard joint body and the driveshaft, and secure with the clips provided.
7. Slide the new outboard gaiter and retaining clip onto the driveshaft and press the joint inner race onto the
driveshaft splines with the match marks aligned (if re-using joint). Retain with a new circlip.
8. Fit the inboard joint body to the shaft assembly with the match marks aligned (if re-using joint), and fit a
new circlip into the end of the housing to retain the joint.
9. Fit gaiter into the grooves on the joint outer body and driveshaft and secure with new gaiter clips.
10. Refit the driveshaft to the car (see above).
Extension Shaft Support Bearing - C64
The ball bearing supporting the RH driveshaft extension shaft to the engine block is mounted in a housing
which is bolted to a bracket on the engine block. The bearing is sealed and maintenance free, and is included
as part of the inboard C.V. joint assembly, but may if necessary be renewed by the following procedure:
1. Remove the RH driveshaft assembly (see above).
2. Using a press, remove the dust shield from the inboard end of the shaft.
3. Remove the circlip from the outboard face of the bearing housing, and press or pull the housing from the
bearing.
Page 16
99-1089#BJ95
Section FJ