Some good news
Discussion
The box is off 
Many many thanks to everyone who has provided input to my threads.
I've spent an entire evening underneath the Lotus repeatedly turning the crankshaft pulley a 6th of a turn using the worlds largest ratchet in the worlds most confined space whilst my step father progressively loosened the 6 allen bolts holding the clutch assembly together. A couple of hours later and the box is off at last!!!!!
The problem with the clutch is that the spline on the 2nd clutch plate is completely torn out and is completely jammed on the input shaft, meaning there was little or no movement in the clutch at all.
The clutch plates themselves are well worn, and are not many thousand miles off of needing replacement. The car's only done 23,000 miles, but I'm guessing the clutch being the way it is would mean that it's been dragging and would so give premature wear?
===================================================
Anyway, some questions if I may;
1) There is movement on the primary shaft. You can grab it and wiggle it up and down/side to side about 5mm. Is this normal or have we foooked something trying to get it out?
There is no {or little} movement if you try to move it towards and away from the box.
2) Can a new clutch be obtained from anywhere other than a Lotus dealer, inc the mandatory Lotus tax. Or do I just get ready to hand over my first born virgin daughter now?
3) When I replace the clutch does it come with a new release bearing or is that something I need to get separetly?
I'm gonna do the leaky output shaft seals as well whilst it's all in bits, any other advice for stuff I should be looking at?
I really cant wait now to get her back on the road, I'm sure that once this is sorted the car is going to be totally transformed
Less Heartbroken Zhastaph
Many many thanks to everyone who has provided input to my threads.
I've spent an entire evening underneath the Lotus repeatedly turning the crankshaft pulley a 6th of a turn using the worlds largest ratchet in the worlds most confined space whilst my step father progressively loosened the 6 allen bolts holding the clutch assembly together. A couple of hours later and the box is off at last!!!!!
The problem with the clutch is that the spline on the 2nd clutch plate is completely torn out and is completely jammed on the input shaft, meaning there was little or no movement in the clutch at all.
The clutch plates themselves are well worn, and are not many thousand miles off of needing replacement. The car's only done 23,000 miles, but I'm guessing the clutch being the way it is would mean that it's been dragging and would so give premature wear?
===================================================
Anyway, some questions if I may;
1) There is movement on the primary shaft. You can grab it and wiggle it up and down/side to side about 5mm. Is this normal or have we foooked something trying to get it out?
There is no {or little} movement if you try to move it towards and away from the box.
2) Can a new clutch be obtained from anywhere other than a Lotus dealer, inc the mandatory Lotus tax. Or do I just get ready to hand over my first born virgin daughter now?
3) When I replace the clutch does it come with a new release bearing or is that something I need to get separetly?
I'm gonna do the leaky output shaft seals as well whilst it's all in bits, any other advice for stuff I should be looking at?
I really cant wait now to get her back on the road, I'm sure that once this is sorted the car is going to be totally transformed
Less Heartbroken Zhastaph
zhastaph said:
1) There is movement on the primary shaft. You can grab it and wiggle it up and down/side to side about 5mm. Is this normal or have we foooked something trying to get it out?
There is no {or little} movement if you try to move it towards and away from the box.
2) Can a new clutch be obtained from anywhere other than a Lotus dealer, inc the mandatory Lotus tax. Or do I just get ready to hand over my first born virgin daughter now?
3) When I replace the clutch does it come with a new release bearing or is that something I need to get separetly?
(Snip)... any other advice for stuff I should be looking at?
Zhastaph,
Good job getting the clutch and transaxle off. When they hang-up like that it's a real pain getting them off. Especially with everything hanging off the end of an engine hoist.
1) There will be some free movement allowed in the end of the input shaft. The spigot bearing in the end of the crankshaft supports the forward end of the shaft after it goes through the clutch.
2) Marcus, SJ Sports Cars, Christopher Neil... etc.
3) Parts are usually sold individually. Order everything one part number at a time unless your supplier specifically states they are selling a "kit" to you. Then know what is in the kit.
Regards,
Tim Engel
Lotus Owners Oftha North
>> Edited by Esprit2 on Thursday 17th March 23:43
Brilliant news, I bet it make you smile when it came off!!
On ms S4s the input shaft to the gearbox moves around as you describe. I have never seen the input shaft bearing the know if its supposed to, although the guide tube that surrounds it is not a close fit, and maybe designed that way to allow movement. Anyway, when its in the spigot bearing it won't move. Mine doesn't whine and went back A OK.
Glyn
On ms S4s the input shaft to the gearbox moves around as you describe. I have never seen the input shaft bearing the know if its supposed to, although the guide tube that surrounds it is not a close fit, and maybe designed that way to allow movement. Anyway, when its in the spigot bearing it won't move. Mine doesn't whine and went back A OK.
Glyn
Great to see that you got it out finally.... very ugly mess however. The AP Racing twin-plate clutch is provided as a complete assembly which contains the release bearing. It is recommended that you not take it apart. There are usually sources other than Lotus for the clutch. As for wear, they should a long time other than the problem you had which was worse than mine. I managed 49K miles on it before replacing it and the discs are still okay and I can still use if needed.
Being in the UK, you might be able to have AP Racing rebuild the clutch assembly. I would be careful on trying to get the jammed disc off as the gearbox input shaft is a 2-piece splined and pinned shaft (which is why it wobbles a bit). Good luck getting it back together and let us know how is runs afterwards.
Regards, KM
2000 V8
Being in the UK, you might be able to have AP Racing rebuild the clutch assembly. I would be careful on trying to get the jammed disc off as the gearbox input shaft is a 2-piece splined and pinned shaft (which is why it wobbles a bit). Good luck getting it back together and let us know how is runs afterwards.
Regards, KM
2000 V8
Hi Colin,
Congratulations ... seems you got the clutch off quite fine ;o)
What you have there is very common. The spline vs. friction disks are seized ... normally there should be some grease on the spline, not rust ;o)
According to your pics the pressure plates look quite bad ... did I see this correctly ? ... Are there blue spots on it ?
If so I would advise to get a complete new clutch kit from Lotus (its the only source IMHO)
If the plates are still in good condition (= no blue spots and not warped) you can get them refurbished (they may take away a very small amount from the surface < 0.1mm)
The friction disk may also get refurbished with new friction material riveted on.
This is a good idea when the plates are still fine and just the disks have gone.
Please dont forget to lube the spline a bit, when you reassemble the whole clutch ...
Cheers
Marcus (www.PUKesprit.de)
>> Edited by Paula&Marcus on Friday 18th March 14:54
Congratulations ... seems you got the clutch off quite fine ;o)
What you have there is very common. The spline vs. friction disks are seized ... normally there should be some grease on the spline, not rust ;o)
According to your pics the pressure plates look quite bad ... did I see this correctly ? ... Are there blue spots on it ?
If so I would advise to get a complete new clutch kit from Lotus (its the only source IMHO)
If the plates are still in good condition (= no blue spots and not warped) you can get them refurbished (they may take away a very small amount from the surface < 0.1mm)
The friction disk may also get refurbished with new friction material riveted on.
This is a good idea when the plates are still fine and just the disks have gone.
Please dont forget to lube the spline a bit, when you reassemble the whole clutch ...
Cheers
Marcus (www.PUKesprit.de)
>> Edited by Paula&Marcus on Friday 18th March 14:54
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