Lotus Eleven/Elise/Exige. Manual

Page 1

Lotus Service Notes

Section FJ

TRANSMISSION

SECTION FJ

Sub-Section Page

Introduction

FJ.1

Gearchange Mechanism

FJ.2

Lubrication

FJ.3

Driveshafts

FJ.4

Transmission Replacement

FJ.5

Transmission Overhaul & Special Tools

FJ.6

See also Toyota transmission repair manual:

1ZZ / 2ZZ - C64/C56 repair manual E120T0327J

1ZR - EC60 repair manual CD T000T1523F

Updated 17th May 2010

Lotus Service Notes

Section FJ

Page 2

FJ.1 - INTRODUCTION

The Elise S 5-speed transmission, the 2ZZ powered Elise/Exige 6-speed transmission, and the 1ZR

powered Elise 6-speed, are all of similar construction, being 'end on' type, mounted on the left hand end of the

engine unit, and comprising the clutch housing, gearbox, final drive gears, and differential. All units are sup-

plied by Toyota, and are designated correspondingly 'C56', 'C64' and EC60 (C = series; 5 or 6 = no. of gears;

6, 4 or 0 = ratio set). Publication E120T0327J covers the repair of the C56 and C60, with CD T000T1523F

covering the EC60.

Two control cables, running along the centre of the cabin and beneath the power unit, are used to transmit

the movement of the gearchange lever to the transmission selector mechanism.

C56 Five Speed

(reverse idler omitted Clutch housing

f138

for clarity)

Clutch splines

5 4 3 2 R 1

End cover

(casting on

Lotus)

Gearbox casing

LH driveshaft

inboard CV joint

Final drive

output gear

Bevel gear

differential

Page 3

Lotus Service Notes

Section FJ

C64 Six Speed

(reverse idler omitted

for clarity) 6 5 4 3 2 R 1

Input shaft

Output shaft

Clutch/Diff

housing

End cover

Gearbox

Centre support casing

bearing

f145

EC60 Six Speed

Reverse idler

6 5 4 3 2 R 1

Input shaft

Output shaft

Clutch/Diff

housing

Gearbox casing

f146

Page 4

Lotus Service Notes

Section FJ

The two shaft, all indirect gearbox, is housed within a two or three part cast alloy casing, including the dry

chamber clutch housing, and secured by threaded fasteners to the back of the engine block. The clutch friction

plate is splined to the gearbox input shaft from which the power flows to the output shaft mounted below it, and

thence to the final drive and differential into which are fitted the driveshafts.

In the C56 5-speed gearbox, ratios 1 to 4 including reverse, are contained within the main case, with the

5th gearset overhung at the rear within an end cover. The input shaft uses a front roller bearing and a rear

ball bearing, as does the output shaft, albeit with a much larger front roller to accommodate the final drive gear

forces. Needle roller bearings are used for each of the free spinning gears, and a pair of taper roller bearings

support the differential assembly. Sychroniser assemblies for 3rd/4th and 5th speeds are mounted on the in-

put shaft, and that for 1st/2nd on the output shaft, with the latter also providing the reverse gear driven pinion

incorporated on its periphery. A reverse gear idler pinion is mounted on its own stub shaft, and may be slid into

engagement with both a gear integral with the input shaft, and the ring gear on the 1st/2nd synchroniser. The

housing for the final drive and differential is shared between the clutch housing and gearbox case, with taper

roller bearings supporting the differential.

The C64 six-speed transmission is a development of the C56, with both shafts extended at the rear to

accommodate the additional ratio. Extra ball bearings are included in the end case to support the tails of each

shaft.

The EC60 6-speed transmission is a further evolution of the C64, but dispenses with the separate end

casing and shaft centre support bearings, using instead, front and rear ball bearings for the input shaft, and

a pair of opposed taper roller bearings for the output shaft. A reverse gear engagement aid is provided by a

mechanism which applies a loading to the 6th gear synchroniser cone, to help stop input shaft rotation, before

the reverse idler gear teeth are slid into engagement.

Lotus Eleven/Elise/Exige. Manual - part 52