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Page 9
Lotus Service Notes
Section CI CI.4 - SUSPENSION DISASSEMBLY/ASSEMBLY The suspension may be disassembled without the use of any special tools other than a 'Torx' socket for the hub bearing carrier bolts, and a spring compressor, required only if the spring is to be removed from the damper unit. With the car on a wheel free lift and with the front wheels removed: 1. Remove the wheelarch liner(s) as appropriate. 2. Remove the two bolts securing the brake calliper to the hub carrier, release the flexible hose from the top wishbone, and support the calliper aside without straining the brake hose. Release the single countersunk screw, and remove the brake disc. 3. Remove the nut securing the track rod end into the steering arm, and use a ball joint splitter to separate the rod end from the arm. 4. Remove the nut securing the top swivel joint to the steering arm, and use a ball joint splitter to separate the joint from the arm. Remove the two M10 fixing bolts and remove the steering arm from the hub carrier, taking care not to misplace the camber adjustment shim plates. 5. Remove the nut securing the lower swivel joint to the hub carrier, and use a ball joint splitter to separate the ball pin from the carrier. 6. Remove the bolts securing the spring/damper unit to the lower wishbone and chassis anchor bracket, and withdraw the unit, noting the spacer washers fitted at the top end. 7. Disconnect the anti-roll bar drop link from the lower wishbone, and remove the lower wishbone front pivot bolt. 8. Remove the lower wishbone rear pivot bolt from within the cabin footwell, and withdraw the wishbone. 9. Before removing the two pivot bolts for the top wishbone, take careful note of the distribution of castor adjustment washers. Move the steering rack to full lock to provide clearance for the withdrawal of the wishbone rear pivot bolt. Withdraw the wishbone. 10. The wishbone pivot bushes comprise a rubber bush bonded to a steel inner sleeve and a flanged plastic outer sleeve. The bushes may be pressed out of the wishbone eyes, and new bushes fitted using suit- able press tool dollies. Smear the outer surface of the new bush with IPC 'P-80' rubber lubricant emulsion (A082C6042V) to ease fitment, and assemble as follows. If possible, warm the wishbone to 80 - 100°C.
Top wishbone - insert from the outside of both pivot eyes (from front of front eye, and rear of rear eye).
Lower wishbone - insert from the inside of both pivot eyes (from rear of front eye, and front of rear eye).
Note that all wishbone pivot bushes are common with the exception of the top wishbone rear pivot, which contains no interleaf sleeve and is identified by a blue paint mark. 11. Top and bottom swivel joints are identical, and may be replaced if necessary using a suitable press. 12. If the anti-roll bar is to be removed; remove the front alloy undertray, and, by drilling out the rivets, the small alloy closing panel at each side of the crash structure below the anti-roll bar. Release the a.r. bar clamps and drop links, and withdraw the bar. 13. The road spring may be removed from the damper using a suitable spring compressor to allow the spring lower slotted seat to be withdrawn. Note that spring upper seat is located by a square section circlip on the damper body:
- Standard Elise: Use centre of 3 grooves for mid-laden ride height of 130mm.
- USA Elise: Use lower of 3 grooves for mid-laden ride height of 135mm.
- Elise with sports suspension package and non-USA Exige: Use the upper of 2 grooves for mid-laden ride height of 130mm. 14. To remove the hub bearing unit from the hub carrier, release the three Torx head bolts and withdraw the complete unit. The hub unit is not serviceable, and is replaced complete if faulty. |