Lotus Eleven/Elise/Exige. Manual - part 56

Page 17

 

 

Lotus Service Notes   

 

 

     Section FJ

4.  Prise or pull the bearing dust shield off the shaft.

5.  Remove the circlip retaining the bearing and press or pull the bearing from the shaft.

6.  Press  a  new  bearing  into  the  housing, 

and retain with a new circlip.  Then use 

special press tool T000T1438F to press 

the inner race of the bearing up to the 

shoulder on the shaft, and retain with a 

new circlip.

7.  Use  special  press  tool T000T1439F  to 

press  the  bearing  dust  shield  onto  the 

shaft and position as shown in the illus-

tration.

8.  Press the inboard dust shield onto the 

end of the shaft to the dimension shown 

in the illustration.

9.  Refit  the  driveshaft  to  the  car  (see 

above).

FJ.5 - TRANSMISSION REPLACEMENT

The transmission may be removed from below after removing the left hand rear suspension assembly,  

both driveshaft assemblies and the exhaust system.  Release the clutch release fork, gearchange cables, earth 

braid and reverse light switch.

The engine must be supported to allow the engine and transmission mountings to be disconnected and 

the power unit tilted as necessary to allow the transmission to be withdrawn.  The clutch bell housing is secured 

to the engine by 8 bolts as shown overleaf.

86.5 ± 0.5mm

           

        

 

 

 

 

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Lotus Service Notes   

 

 

     Section FJ

Page 18

FJ.6 - TRANSMISSION OVERHAUL

The overhauling of the Toyota supplied type C64/C56 transmission, is detailed in separate publication 

E120T0327J.  

For the EC60 transmission, a CD under part number T000T1523F is available; choose:

- 

Repair Manual

- 

Transmission

- 

scroll down to find EC60 MANUAL TRANSAXLE in left hand column.

When applicable, select '2010/01 -'

Clutch housing to engine fixings - viewed from gearbox side (2ZZ shown)

               M12x55 flange head bolts to block; 64 Nm

M10x65 bolts also secure                                        M10x55 bolts to

starter motor; 37 Nm                                          block; 37 Nm

                               

          

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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             M10x30 bolts to sump; 23 Nm

Page 19

 

 

Lotus Service Notes   

 

 

     Section FJ

Transmission Special Tools

Description                            Lotus Part No.  

Press Dolly, driveshaft bearing   

 

 

T000T11438F   

 

Press Dolly, driveshaft bearing shield 

 

 

T000T1439F   

 

Oil Seal Puller   

 

 

 

 

T000T1445S

Differential Preload Adaptor 

 

 

 

T000T1446S

5th/6th Gear Puller Kit   

 

 

 

T000T1447

comprises:

 

Upper Plate 

 

 

 

 

T000T1447/1

 

Centre Bolt 

 

 

 

 

T000T1447/2

 

Arm (x3)   

 

 

 

 

T000T1447/3

 

Adaptor   

 

 

 

 

T000T1447/4

5th/6th Synchro Hub Puller Kit   

 

 

T000T1448

comprises

 

Hanger   

 

 

 

 

T000T1448/1

 

Slide Arm (x2) 

 

 

 

 

T000T1448/2

 

Centre Bolt 

 

 

 

 

T000T1448/3

 

Claw no.2 (x2) 

 

 

 

 

T000T1448/4

 

Holder 

 

 

 

 

 

T000T1448/5

Output Shaft Seal Replacer Dolly, LH   

 

T000T1459F

Output Shaft Seal Replacer Dolly, RH   

 

T000T 

Output Shaft Seal Replacer Handle 

 

 

T000T1460F

Transmission Overhaul Notes

1.  Removing and installing 5th and 6th driven gears from the end of the ouput shaft requires considerable 

force.  The specified puller tools should be used, but when pulling 5th speed driven gear, the claws of the 

tool may require some grinding to allow complete and proper fitment, and an anti-spreading device is rec-

ommended to be fitted around the three claws.  Striking the puller bolt with a hammer in between tightening 

steps will help shock the gear from its interference fit, and engaging two gears to lock the transmission 

will also aid the process.

2.  The preload on the differential carrier taper roller bearings is controlled by shims between the bearing 

outer race and the clutch housing, and is determined by installing the final drive assembly in an otherwise 

empty casing, and measuring the steady rotation torque.

3.  If the input shaft oil seal is to be replaced, the bearing should also be renewed since this is likely to be 

damaged during oil seal removal.

4.  The transmission cross-shaft reverse select compression spring shown in the Toyota Repair Manual is 

removed for the Lotus application.  When fitting a replacement transmission, compare the cross shaft 

spring loading of the old and new units to determine whether this modification has been carried out.

Page 20

 

 

Lotus Service Notes   

 

 

     Section FJ

5.  For cars fitted with a limited slip differential, note the following:

- 

Apart from the taper roller bearings supporting the differential assembly in the transmission case, the unit 

is not serviceable.

- 

The tightening torque of the bolts securing the final drive gear to the differential assembly = 101 Nm (Std. 

diff. = 77 Nm).

- 

When setting the differential bearing preload (see page 41-28 in Toyota manual D120T0327J) note that a 

different procedure must be used due to the construction of the LSD.  Instead of fitting only the differential 

assembly into the transaxle/transmission case, and then measuring the turning torque directly at the dif-

ferential, LSD versions require that the differential and output shaft be assembled into the casings, and 

the turning torque measured by using a torque wrench (27mm socket) on the end of the output shaft.

- 

Bearing preload (at starting):

New bearings:  0.17 - 0.35 Nm (1.7 - 3.6 kgf.cm)

Used bearings:  0.11 - 0.22 Nm (1.1 - 2.2 kgf.cm)

- 

Adjustments are made as for non-LSD.

- 

There is no special oil requirement for the LSD.

                                Torque wrench

                                                                        

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