Lotus 2004 Eleven Service Notes page 266

Lotus Service Notes
JJ.11 - PEDAL BOX
PRIOR TO '06 M.Y.
The extruded and welded aluminium alloy pedal box is bonded and rivetted to an aperture in the chassis
scuttle. A hollow steel pivot shaft serving all three pedals is bolted to a steel mounting plate, itself bolted to the
inside of the pedal box. Each pedal is machined from a common alloy extrusion, with the throttle pedal being
of a narrower section than that used for the brake and clutch. An extruded footpad is keyed, bonded and
rivetted to the clutch and brake pedals, and is bolted to the throttle pedal. All the pedals use synthetic bushes
for maintenance free articulation on the steel pivot shaft, and the clutch pedal uses a cylindrical steel trunnion
supported in synthetic bearing rings to actuate the master cylinder pushrod.
In order for the required pedal spacing to be achieved within the packaging constraints of the vehicle, the
brake pedal uses a relay lever to move the output plane inboard of the pedal line. A steel relay lever pivots on
the common pedal shaft, and is equipped with two legs, one of which is used to connect to the brake pedal via
an integral trunnion, whilst the other leg is connected to the brake servo pushrod by a clevis pin.
The throttle pedal actuates the throttle cable directly, which is routed along the cockpit centre, beneath the
gear lever and parking brake lever trim panels, beneath the fuel tank bay and up to the front of the engine bay
to the throttle body.
Adjustment
Throttle cable:
- The pedal is pulled against a rubber buffer on a steel upstop bracket by an extension spring.
- Adjust the cable outer length at the engine end abutment bracket to allow 2 - 3mm of pedal movement
before the throttle is actuated.
- Set the downstop in the pedal footpad such that vigorous full depression of the pedal achieves full
opening of the throttle butterfly without allowing the cable to be strained.
- An alternative pedal position which may be preferred for 'heel and toeing' may be achieved by replacing
the rubber upstop buffer with a M5x15 hex. head setscrew, with three flat washers beneath the head for a
total thickness of around 7mm. The cable must then be re-adjusted at the engine abutment as above.
The footpad downstop bolt should then be replaced by an M8x20 setscrew and reset as above.
Brake pedal:
- The pedal is pulled 'off' by an extension spring anchored to a bracket rivetted to the scuttle beam.
- There is normally a gap of approximately 3mm between the brake pedal and the pedal box upstop flange
with the pedal released. If preferred, the brake pedal can be raised slightly by adjusting the effective
length of the pushrod at its connection to the clevis, but the master cylinder must never be preloaded, i.e.
there must always be a small clearance between the pedal and upstop bracket to ensure that the master
cylinder piston is allowed fully to return and open the reservoir port.
- After any adjustment, tighten the clevis locknut and check operation of the brake light switch.
Clutch pedal:
- The pushrod, which is captive in the master cylinder, is screwed fully into the pedal trunnion, and controls
the pedal height. Rubber buffers are provided to cushion the pedal at full travel.
Pedal Removal
To remove a pedal from the pivot shaft, the pedal shaft mounting plate must be removed from the pedal
box complete with all three pedals:
1. Remove the intermediate steering column (see Section HG).
2. Disconnect the brake servo clevis pin from the pedal relay lever, and release the throttle cable from the
pedal.
3. Remove the two bolts securing the clutch master cylinder assembly to the pedal box and unscrew the
pushrod from the pedal trunnion.
4. Remove the two bolts securing the brake servo mounting plinth to the pedal box and provide alternative
support for the servo/brake master cylinder assembly.
Section JJ
Page 21