The project begins
Discussion
Well, my Esprit is officially off the road for various maintenance items and several upgrades. So... a long post to start with.
First, impressions after 42K miles in 3 years. Overall, car is wonderful, every drive still brings a smile to my face and the feeling of wanting to climb back in right after you finish a drive.... yes, it's still addictive.
My engine has been rock solid... I had the dealer perform two cambelt checks (6K and 18K) and I did a 3rd belt tension at 32K (they were flapping). Beyond this, the only problems near the engine have been the A/C compressor... went twice along with a few sets of manifold pipes and the water pump almost fell out at 12K miles... bolts just loosened up, coolant went out real fast. But in general, the engine is one excellent powerplant.
The chassis and body have been near flawless. The rear lower links have an angle problem and literally shear off the bushing shoulder religiously. The AP Racing brakes are excellent and still have meat left on the pads (F/R) after 42K miles... simply amazing. Other issues have been a bad radiator, two bad cooling fans and a few other minor bits.
The real challenge has been gearbox problems. It turns out I have a defective AP Racing twin-plate clutch, it drags in general, sometimes very heavily. After wiping out the synchros in the original box at 18K miles, the dealer diagnosed only a defective gearbox. I asked them to check the clutch and they said it was fine. After replacing the gearbox with a "remanufactured gearbox" (which scares the hell out of me) it has actually held up better but the synchros are shot and the clutch needs replacing. It doesn't slip one bit and I'm curious to measure the friction plates and compare to the new clutch assembly I have.
So I will rebuild the gearbox with new synchros and add a quaife atb diff. I'm also looking into having a one-piece input shaft made of a harder steel but in stock dimensions sans the weak 5th gear relief areas and splining. The goal is for a one-piece direct replacement which should make the gearbox hold up much better with increased torque/power.
Next, exhaust. Yes, all the mufflers crack (if you drive the car) and my 4th is shot now as well. Amazingly enough, zero problems with the catalytic convertors and O2 sensors. Turbos as well... zero problems. But I have the Hyper-FLow Stainless cats here and am waiting for the matching Stainless exhaust to replace all of the original.
The radiator left today for Griffin Thermal Products. It will be used as a pattern to build a higher-capacity alloy replacement which is lighter and will have a trio of Spal fans and a temperature sensor in the outlet tank. I'll use this to sense temperature creep when in stop/go traffic and engage the fans at lower speeds to provide regulation of the engine temperature. The same will apply to the oil coolers.
All in all, I expect the car to be lift-bound for 6 weeks at a minimum. Wish me luck.... cambelt replacements are next week.
Some updates/enhancements I've made so far include:
- Sylvania XR5006 lighting upgrade. True Xenon HID dip beams and Halogen H1 Mains, all with polycarbonate lenses.
- Lotus alloy door sills and rear esprit decal
- 2002 wiper blade (doesn't jump around at high speed)
- Raid airbag steering wheel - Thanks Jim and Karl!
- ITG Oiled-Foam air filters
- CM Filters synthetic oil filter for engine
- small alloy antenna replaces long VW whip
Regards, KM
2000 V8 - a great 42K mile story with a re-write coming soon
First, impressions after 42K miles in 3 years. Overall, car is wonderful, every drive still brings a smile to my face and the feeling of wanting to climb back in right after you finish a drive.... yes, it's still addictive.
My engine has been rock solid... I had the dealer perform two cambelt checks (6K and 18K) and I did a 3rd belt tension at 32K (they were flapping). Beyond this, the only problems near the engine have been the A/C compressor... went twice along with a few sets of manifold pipes and the water pump almost fell out at 12K miles... bolts just loosened up, coolant went out real fast. But in general, the engine is one excellent powerplant.
The chassis and body have been near flawless. The rear lower links have an angle problem and literally shear off the bushing shoulder religiously. The AP Racing brakes are excellent and still have meat left on the pads (F/R) after 42K miles... simply amazing. Other issues have been a bad radiator, two bad cooling fans and a few other minor bits.
The real challenge has been gearbox problems. It turns out I have a defective AP Racing twin-plate clutch, it drags in general, sometimes very heavily. After wiping out the synchros in the original box at 18K miles, the dealer diagnosed only a defective gearbox. I asked them to check the clutch and they said it was fine. After replacing the gearbox with a "remanufactured gearbox" (which scares the hell out of me) it has actually held up better but the synchros are shot and the clutch needs replacing. It doesn't slip one bit and I'm curious to measure the friction plates and compare to the new clutch assembly I have.
So I will rebuild the gearbox with new synchros and add a quaife atb diff. I'm also looking into having a one-piece input shaft made of a harder steel but in stock dimensions sans the weak 5th gear relief areas and splining. The goal is for a one-piece direct replacement which should make the gearbox hold up much better with increased torque/power.
Next, exhaust. Yes, all the mufflers crack (if you drive the car) and my 4th is shot now as well. Amazingly enough, zero problems with the catalytic convertors and O2 sensors. Turbos as well... zero problems. But I have the Hyper-FLow Stainless cats here and am waiting for the matching Stainless exhaust to replace all of the original.
The radiator left today for Griffin Thermal Products. It will be used as a pattern to build a higher-capacity alloy replacement which is lighter and will have a trio of Spal fans and a temperature sensor in the outlet tank. I'll use this to sense temperature creep when in stop/go traffic and engage the fans at lower speeds to provide regulation of the engine temperature. The same will apply to the oil coolers.
All in all, I expect the car to be lift-bound for 6 weeks at a minimum. Wish me luck.... cambelt replacements are next week.
Some updates/enhancements I've made so far include:
- Sylvania XR5006 lighting upgrade. True Xenon HID dip beams and Halogen H1 Mains, all with polycarbonate lenses.
- Lotus alloy door sills and rear esprit decal
- 2002 wiper blade (doesn't jump around at high speed)
- Raid airbag steering wheel - Thanks Jim and Karl!
- ITG Oiled-Foam air filters
- CM Filters synthetic oil filter for engine
- small alloy antenna replaces long VW whip
Regards, KM
2000 V8 - a great 42K mile story with a re-write coming soon
Sounds like you have some intresting fun work ahead, and car should be all the better by the end of it.
You mentined getting work done on the gearbox and if you haven't already seen the site I would suggest a look at Derek Bell's input shaft upgrade which has already been successfully put into an Esprit gearbox.
www.bell-performance.co.uk/
After meeting and talking to him at the UK oxford meet a little while ago he certainly knows what he is on about, and even the Lotus engineers agree his mod is a good thing by a person who is very knowledgable.
Good luck with all the mods.
Del
95 S4s
>> Edited by Del-Esprit on Sunday 10th October 17:27
You mentined getting work done on the gearbox and if you haven't already seen the site I would suggest a look at Derek Bell's input shaft upgrade which has already been successfully put into an Esprit gearbox.
www.bell-performance.co.uk/
After meeting and talking to him at the UK oxford meet a little while ago he certainly knows what he is on about, and even the Lotus engineers agree his mod is a good thing by a person who is very knowledgable.
Good luck with all the mods.
Del
95 S4s
>> Edited by Del-Esprit on Sunday 10th October 17:27
williamives said:
my car's running with the 'Derek Bell' gearbox upgrade. (after failing at the 5th gear weak spot) I'm very happy with the result, and I can highly recommend it. If you want more info let me know.
Will
'99 Sport 350 #004
I swapped email with Derek a good 18 months ago and yes, his upgrade kit is quite nice and very well done. What wasn't clear was how the altered gear ratios (1st/2nd) would affect the ECM and how to handle the spline change as it is both different in splining and the length of the splined surface.
If you have installed this kit into your gearbox with the Sport 350, how did you resolve the clutch setup? Did Derek make a new input shaft with the Renault splining which is compatible with the AP Racing twin-plate clutch? I'd like to know how you fitted everything if you don't mind sharing.
Regards, KM
2000 V8
KM - i met Derek Bell at the recent oxford exprit meet. He is making an esprit upgrade package, details shortly to be on LEW. He's looking for five orders to get the ball rolling. I gave him my details but to be honest i don't have the cash right now.. 
Will's car uses a generic AP clutch - the "lotus-only" part can't be sold direct by AP due to contractural restrictions imposed by lotus. Will managed to get them to supply a virtually identical generic twin plate clutch with splines to match Derek's shaft. As this then isn't the same as the lotus part, it can be sold direct. Will was quoting approx £500 which is a useful saving over the lotus item.
I had a quick 'stir' of will's gearbox in the carpark at the oxford meet. First can balk sometimes (its straight cut) but not so much that it would be an issue in normal use. Will's already done several thousand miles on his re-built box with no issues so far.
Once Derek Bell has five orders, he's going to make up 10 kits (i think) so he can keep some stock for future orders. If we don't get the requisite 5 orders i don't think this will progress which is a shame.
Interesting also to hear Brian A. of lotus cars talking about the gearbox work Derek is doing - seems the factory are going as far as they can to give their backing but stopping short of offering it as an approved modification- i suppose for product liability/type approval reasons. The work Derek has done addresses the known shortcomings of the box, and Derek's experience of renault box failures matches what the factory have seen.
Money no object, i'd have the quaife lsd and Derek's kit in my car, no question.
Maybe next year
Will's car uses a generic AP clutch - the "lotus-only" part can't be sold direct by AP due to contractural restrictions imposed by lotus. Will managed to get them to supply a virtually identical generic twin plate clutch with splines to match Derek's shaft. As this then isn't the same as the lotus part, it can be sold direct. Will was quoting approx £500 which is a useful saving over the lotus item.
I had a quick 'stir' of will's gearbox in the carpark at the oxford meet. First can balk sometimes (its straight cut) but not so much that it would be an issue in normal use. Will's already done several thousand miles on his re-built box with no issues so far.
Once Derek Bell has five orders, he's going to make up 10 kits (i think) so he can keep some stock for future orders. If we don't get the requisite 5 orders i don't think this will progress which is a shame.
Interesting also to hear Brian A. of lotus cars talking about the gearbox work Derek is doing - seems the factory are going as far as they can to give their backing but stopping short of offering it as an approved modification- i suppose for product liability/type approval reasons. The work Derek has done addresses the known shortcomings of the box, and Derek's experience of renault box failures matches what the factory have seen.
Money no object, i'd have the quaife lsd and Derek's kit in my car, no question.
Maybe next year
rob.e said:
KM - i met Derek Bell at the recent oxford exprit meet. He is making an esprit upgrade package, details shortly to be on LEW. He's looking for five orders to get the ball rolling. I gave him my details but to be honest i don't have the cash right now..
Will's car uses a generic AP clutch - the "lotus-only" part can't be sold direct by AP due to contractural restrictions imposed by lotus. Will managed to get them to supply a virtually identical generic twin plate clutch with splines to match Derek's shaft. As this then isn't the same as the lotus part, it can be sold direct. Will was quoting approx £500 which is a useful saving over the lotus item.
I had a quick 'stir' of will's gearbox in the carpark at the oxford meet. First can balk sometimes (its straight cut) but not so much that it would be an issue in normal use. Will's already done several thousand miles on his re-built box with no issues so far.
Once Derek Bell has five orders, he's going to make up 10 kits (i think) so he can keep some stock for future orders. If we don't get the requisite 5 orders i don't think this will progress which is a shame.
Interesting also to hear Brian A. of lotus cars talking about the gearbox work Derek is doing - seems the factory are going as far as they can to give their backing but stopping short of offering it as an approved modification- i suppose for product liability/type approval reasons. The work Derek has done addresses the known shortcomings of the box, and Derek's experience of renault box failures matches what the factory have seen.
Money no object, i'd have the quaife lsd and Derek's kit in my car, no question.
Maybe next year
Rob, Thanks for the info... I'll send Derek an email... and get signed up for the upgrade kit... ugh, more $$ to find but I do have the Quaife LSD here already.
Regards, KM
2000 V8
ErnestM said:
Sorry for the late post...
Kevin...
I would be very interested on your review of the hyperflow cats. They are also on my shopping list for early next year install. Kudos, issues, acclaims or pitfalls would be appreciated...
ErnestM
Hi Ernest,
Sorry for the late reply.. been a hectic week. I don't plan to install them until I get a matching muffler as my 4th is cracked and rattling. However, seems the world of Lotus suppliers has picked up on them and now sells them. Luke Walling on the TE list just picked up a set and will be installing them soon so I plan on checking in with him shortly to see what he thinks. I must say they are very nicely done and according to Hyper-Flow have increased flow by 50%. Also note they only use a single metal cat element which differs from the pre/post ceramic cat elements that Lotus uses. They also weigh in at less than 7 pounds each and are less bulky than stock. I also plan on using heatshield products Inferno wrap to insulate the new cats and their turbo blankets as well.
Regards, KM
2000 V8
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