https://wikilec.com/api.php?action=feedcontributions&feedformat=atom&user=Rip 2026-08-14T11:47:14Z User contributions MediaWiki 1.23.9 https://wikilec.com/view/Gearbox_Oil_Change 2018-11-26T09:59:33Z

<p>Rip: /* Capacity and recommended lubricant */</p> <hr /> <div>The challenge lays not in removing oil but putting it in. The transmission is filled through the hole where the speedometer drive cable enters the housing. The first job is to remove the [[Speedometer Cable]] and speedometer gear from the gearbox and remove the speedometer gear to check the oil level. Please do this before draining the old lubricant. If you're not able to remove the cable, it's better to find out while there's still oil in the transmission.<br /> <br /> If you need to add or refill oil you’ll need a funnel and suitable length of hose (nobody said this was easy). The original Mobil oil specified by Lotus is no longer produced. Lotus next recommended Castrol TAF-X 75W-90. TAF-X 75W-90 is no longer available but has been replaced with another Castrol product (see below). Draining the gearbox is simply a case of removing the transmission drain plug from beneath the car. The LEC how-to section includes an [http://www.lotuselancentral.com/repair/transaxleoil.htm article with photographs].<br /> <br /> == Capacity and recommended lubricant ==<br /> Lotus manuals state 1.8l / 1.9 US quarts as capacity for refilling a drained transaxle. 1.9 US quarts = 1.8l = 3 imperial pints = 60.8 fl oz.<br /> <br /> Recommended lubricant is discussed at length in [http://forum.lotuselancentral.com/viewtopic.php?f=122&amp;t=19171 this forum thread] and [http://forum.lotuselancentral.com/viewtopic.php?f=48&amp;t=7835 this one]. Castrol TAF-X 75w90 originally recommended by Lotus is discontinued. As of 2011, it is replaced by Castrol Syntrans 75W-90 in the UK, Syntrax 75w-90 in the US. Redline MT-90 (''not'' MTL) also meets these requirements. For those who have installed Quaife differentials, [http://www.quaife.co.uk/faqs they also recommend] 75W-90 synthetic gear oil.<br /> <br /> Bottom line: 75W-90 GL-4 full synthetic gear oil.<br /> <br /> == The mysterious refill plug ==<br /> <br /> Some may have one. Some may not. [http://www.lotuselancentral.com/forum/viewtopic.php?t=5127 Read on!]<br /> <br /> [[Category:HowTo]]<br /> [[Category:TextToCopyFromLEC]]<br /> [[Category:Maintenance]]</div>

Rip https://wikilec.com/view/Light_pod_debouncing 2013-10-30T21:30:58Z

<p>Rip: </p> <hr /> <div>On Motorway driving at night I had noticed my headlights flickering on roadsigns as I passed. They also looked like they were rather high and could be blinding other drivers.<br /> <br /> I decided to investigate further and discovered I could lift the head lamp pods up and down 10mm or more.<br /> <br /> I discovered that there are effectively 8 ball joints in the headlamp mechanism. At least some of them were very loose.<br /> <br /> I repaired the problem as follows :-<br /> <br /> 1. Open the bonnet and locate the headlamp motor.<br /> <br /> [[Image:Headlightpodmotormanualscrew-1-.jpg|150px]]<br /> <br /> 2. Turn the knob by hand to lift the pod manually<br /> <br /> [[Image:Headlightwoundupmanually-1-.jpg|150px]]<br /> <br /> 3. Remove the 6 screws holding the two headlights in place. Turning any of the others will upset your headlight alignment.<br /> <br /> [[Image:Headlightsup-1-.jpg|150px]]<br /> <br /> 4. Remove the left hand pod pivot bolt using a suitable 5mm Allen Key.<br /> <br /> [[Image:Removelefthandpivotboltusingallenkey-1-.jpg|150px]]<br /> <br /> 5. Remove the right hand pod pivot bolt using a suitable 5mm Allen Key.<br /> <br /> [[Image:Removerighthandpivotboltusingallenkey-1-.jpg|150px]]<br /> <br /> 6. A 10mm Socket with extension bar can now be used to remove the main pivot bolt.<br /> <br /> [[Image:Removepivotnuttoreleasepodfrommotor-1-.jpg|150px]]<br /> <br /> 7. The headlamp pod can now be lifted away to reveal the pod bracket and relay lever.<br /> <br /> [[Image:Headlightssittinginheadlamppodwell-1-.jpg|150px]]<br /> <br /> 8. Remove the left hand pivot bolt first as this will give better access to the right hand pivot bolt.<br /> <br /> [[Image:Removelefthandpivotboltfirst-1-.j|150px]]<br /> <br /> 9. Now remove the right hand pivot bolt<br /> <br /> [[Image:Removerighthandpivotbolt-1-.jpg|150px]]<br /> <br /> 10. The Relay lever can now be removed for further inspection.<br /> <br /> [[Image:Podrelayleverremoved-1-.jpg|150px]]<br /> <br /> 11. Inspecting the lever revealed that the ball joints were fine but the pop rivets holding them on had worked loose.<br /> <br /> [[Image:Pivotremovedfromcar-1-.jpg|150px]]<br /> <br /> 12. The rivets were drilled out, ground off and replaced.<br /> <br /> [[Image:Newrivetsinstalled-1-.jpg|150px]]<br /> <br /> 13. I now turned my attention to the balljoints inside the pod itself. The pop rivets were also loose but rather than remove them I decided to tighten them using a small G clamp.<br /> <br /> [[Image:Gclampusedtotightenrivetsinpod-1-.jpg|150px]]<br /> <br /> 14. This made them slop free once more.<br /> <br /> [[Image:Closeupgclampusedtotightenrivetsinpod-1-.jpg|150px]]<br /> <br /> The headlamp pod was reassembled and is now slop free. The only flexing in the system is now the glass fibre pod itself.<br /> <br /> Next job - new delrin inserts in headlamp motor<br /> <br /> <br /> <br /> Alan Head</div>

Rip https://wikilec.com/view/File:Closeupgclampusedtotightenrivetsinpod-1-.jpg 2013-10-30T21:25:20Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Gclampusedtotightenrivetsinpod-1-.jpg 2013-10-30T21:24:30Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Newrivetsinstalled-1-.jpg 2013-10-30T21:23:53Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Pivotremovedfromcar-1-.jpg 2013-10-30T21:23:10Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Podrelayleverremoved-1-.jpg 2013-10-30T21:22:17Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Removerighthandpivotbolt-1-.jpg 2013-10-30T21:21:34Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Removelefthandpivotboltfirst-1-.jpg 2013-10-30T21:20:47Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Headlightssittinginheadlamppodwell-1-.jpg 2013-10-30T21:19:56Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Removepivotnuttoreleasepodfrommotor-1-.jpg 2013-10-30T21:19:09Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Removerighthandpivotboltusingallenkey-1-.jpg 2013-10-30T21:18:10Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Removelefthandpivotboltusingallenkey-1-.jpg 2013-10-30T21:17:19Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Headlightsup-1-.jpg 2013-10-30T21:16:33Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Headlightwoundupmanually-1-.jpg 2013-10-30T21:15:51Z

<p>Rip: Bouncy pods</p> <hr /> <div>Bouncy pods</div>

Rip https://wikilec.com/view/File:Headlightpodmotormanualscrew-1-.jpg 2013-10-30T21:15:10Z

<p>Rip: Bouncy Pods</p> <hr /> <div>Bouncy Pods</div>

Rip https://wikilec.com/view/Light_pod_debouncing 2013-10-30T21:07:51Z

<p>Rip: New page: On Motorway driving at night I had noticed my headlights flickering on roadsigns as I passed. They also looked like they were rather high and could be blinding other drivers. I decided to...</p> <hr /> <div>On Motorway driving at night I had noticed my headlights flickering on roadsigns as I passed. They also looked like they were rather high and could be blinding other drivers.<br /> <br /> I decided to investigate further and discovered I could lift the head lamp pods up and down 10mm or more.<br /> <br /> I discovered that there are effectively 8 ball joints in the headlamp mechanism. At least some of them were very loose.<br /> <br /> I repaired the problem as follows :-<br /> <br /> <br /> 1. Open the bonnet and locate the headlamp motor.<br /> <br /> Image<br /> <br /> 2. Turn the knob by hand to lift the pod manually<br /> <br /> Image<br /> <br /> 3. Remove the 6 screws holding the two headlights in place. Turning any of the others will upset your headlight alignment.<br /> <br /> Image<br /> <br /> 4. Remove the left hand pod pivot bolt using a suitable 5mm Allen Key.<br /> <br /> Image<br /> <br /> 5. Remove the right hand pod pivot bolt using a suitable 5mm Allen Key.<br /> <br /> Image<br /> <br /> 6. A 10mm Socket with extension bar can now be used to remove the main pivot bolt.<br /> <br /> Image<br /> <br /> 7. The headlamp pod can now be lifted away to reveal the pod bracket and relay lever.<br /> <br /> Image<br /> <br /> 8. Remove the left hand pivot bolt first as this will give better access to the right hand pivot bolt.<br /> <br /> Image<br /> <br /> 9. Now remove the right hand pivot bolt<br /> <br /> Image<br /> <br /> 10. The Relay lever can now be removed for further inspection.<br /> <br /> Image<br /> <br /> 11. Inspecting the lever revealed that the ball joints were fine but the pop rivets holding them on had worked loose.<br /> <br /> Image<br /> <br /> 12. The rivets were drilled out, ground off and replaced.<br /> <br /> Image<br /> <br /> 13. I now turned my attention to the balljoints inside the pod itself. The pop rivets were also loose but rather than remove them I decided to tighten them using a small G clamp.<br /> <br /> Image<br /> <br /> 14. This made them slop free once more.<br /> <br /> Image<br /> <br /> The headlamp pod was reassembled and is now slop free. The only flexing in the system is now the glass fibre pod itself.<br /> <br /> Next job - new delrin inserts in headlamp motor<br /> <br /> <br /> <br /> Alan Head</div>

Rip https://wikilec.com/view/Gearbox_removal 2013-10-30T20:59:58Z

<p>Rip: </p> <hr /> <div>1. Start by jacking up car, removing front wheels, pop out wheel centres, put wheels back on and loosen drive shaft nuts.<br /> <br /> [[Image:Loosendriveshaftnuts.jpg|150px]]<br /> <br /> 2. Jack up car, remove front wheel, place another jack at the inner jacking point at the rear of the prongeron and raise the car.<br /> <br /> [[Image:Removewheel-1-.jpg|150px]]<br /> <br /> 3. Now put car on axle stands at normal front jacking points. I have also placed a block of wood under the sills just in case!<br /> <br /> [[Image:Supportonaxlestands-1.jpg|150px]]<br /> <br /> 4. Now open the bonnet and remove the air filter and associated pipe work<br /> <br /> [[Image:Removeairfilter-1-.jpg|150px]]<br /> <br /> 5. Remove the clutch cable from the clutch lever. At this point it is also worth removing the bolt that holds on the expansion bottle.<br /> <br /> [[Image:Removeclutchcablefrombracket-1-.jpg|150px]]<br /> <br /> 6.Remove the clutch cable from the guide bracket.<br /> <br /> [[Image:Removegearsmallselectorpinandcable-1-.jpg|150px]]<br /> <br /> 7. Remove the spring clip from the smaller of the two gear selector cables and pop off the cable.<br /> <br /> [[Image:Removelargegearselectorcablepin-1-.jpg|150px]]<br /> <br /> 8. Remove the spring clip from the larger gear selector cable.<br /> <br /> [[Image:Removelargegearselectorcable-1-.jpg|150px]]<br /> <br /> 9. Pop off the larger gear selector cable from its pin.<br /> <br /> [[Image:Removespeedocable-1-.jpg|150px]]<br /> <br /> 10. Remove the speedo cable by removing the 10mm nut and clamp plate.<br /> <br /> [[Image:Removegearselectorcablebracket-1-.jpg|150px]]<br /> <br /> 11. Remove the three bolts that hold on the gear selector cable mounting bracket. This avoids accidently adjusting the cable lengths.<br /> <br /> [[Image:Disconnectreversinglightswitch-1-.jpg|150px]]<br /> <br /> 12. Disconnect the wiring from the reversing light switch.<br /> <br /> Its now time to work under the car.<br /> <br /> [[Image:Draingearboxoil-1-.jpg|150px]]<br /> <br /> 13. Drain the gearbox oil by removing the drain plug.<br /> <br /> [[Image:Removecaliperandtopballjoint-1-.jpg|150px]]<br /> <br /> 14. Unbolt the top wishbone ball joint. Take note of how many shims are placed in front of and behind the balljoint. there should be 8 shims in total for each ball joint. In my car there are also inserts to set the camber. Remove the brake caliper and tie it up out of the way. <br /> <br /> The drive shaft nuts can now be removed. <br /> <br /> The nearside drive shaft should be pushed through the hub and then popped or levered out of the gearbox. This can be a fiddle as it is held in place by a snap ring. Do not pull the driveshaft out as this might damage the inner plunge joint.<br /> <br /> The off side drive shaft should be removed by removing the jackshaft bracket bolts then pushing the driveshaft through the hub. The offside driveshaft has no circlip at the gearbox and will slip out easily.<br /> <br /> The drive shafts can be left supported by the suspension yolks but make sure they are not in the way of the gearbox.<br /> <br /> [[Image:Prongeronfront-1-.jpg|150px]]<br /> <br /> [[Image:Prongerondamperandbellhousingbolts-1-.jpg|150px]]<br /> <br /> [[Image:Prongeronviewonramp-1-.jpg|150px]]<br /> <br /> At this point support the gearbox and engine from above or below using a trolley jack.<br /> <br /> I used a bracket to support the engine from above and I placed a trolley jack under the sump. I also put a strap around the gearbox and over the support frame up above.<br /> <br /> 15. Remove the progeron and the front damper along with two of the bellhousing bolts. Start at the front of the car and work your way back.<br /> <br /> [[Image:Removeexhaustdownpipe-1-.jpg|150px]]<br /> <br /> 16. Now remove the exhaust downpipe<br /> <br /> [[Image:Remove4boltsfromflywheelcoverplate-1-.jpg|150px]]<br /> <br /> 17. Remove the four bolts securing the flywheel cover plate.<br /> <br /> [[Image:Removerearenginemountbracket-1-.jpg|150px]]<br /> <br /> <br /> 18. Its time to remove the rear engine mount bracket.<br /> <br /> <br /> [[Image:Frontgearboxmount-1-.jpg|150px]]<br /> <br /> 19. Now remove the gearbox mount. This has several parts, a damper and a couple of L shaped spacer plates.<br /> <br /> [[Image:Finaltopbellhousingbolt-1-.jpg|150px]]<br /> <br /> [[Image:Thirdtopbellhousingboltviewedthroughwheelarch-1-.jpg|150px]]<br /> <br /> [[Image:Anothertopbellhousingbolt-1-.jpg|150px]]<br /> <br /> [[Image:Gearboxinitialalignmentfrombelow-1-.jpg|150px]]<br /> <br /> 20. the only thing holding the gearbox on now is three bell housing bolts at the top. These are a bit awkward to get to.<br /> <br /> [[Image:|150px]]<br /> <br /> 21. The gearbox can now be pulled free from the engine and lowered to the floor.<br /> <br /> A few things worth considering before putting it all back together.<br /> <br /> It is worth trial fitting the mounts onto the gearbox as you will find you have an awful lot of bits lying around.<br /> <br /> [[Image:Gearboxnearsidemounttempfitted-1-.jpg|150px]]<br /> <br /> [[Image:Gearboxnearsidemounttempfitted2-1-.jpg|150px]]<br /> <br /> [[Image:Gearboxnearsidemounttempfitted3-1-.jpg|150px]]<br /> <br /> Start with the gearbox mount<br /> <br /> [[Image:Gearboxrearenginemounttempfitted-1-.jpg|150px]]<br /> <br /> Then the rear engine mount<br /> <br /> [[Image:Gearboxinitialalignment-1-.jpg|150px]]<br /> <br /> Aligning the box is quite tricky but perseverence will pay off.<br /> <br /> I hope this post will help anyone considering removing their gearbox or changing a clutch on their Elan.</div>

Rip https://wikilec.com/view/Gearbox_removal 2013-10-30T20:47:16Z

<p>Rip: </p> <hr /> <div>1. Start by jacking up car, removing front wheels, pop out wheel centres, put wheels back on and loosen drive shaft nuts.<br /> <br /> <br /> <br /> [[Image:Loosendriveshaftnuts.jpg|150px]]<br /> <br /> <br /> 2. Jack up car, remove front wheel, place another jack at the inner jacking point at the rear of the prongeron and raise the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/supportonaxlestands.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/supportonaxlestands.jpg[/img][/url]<br /> <br /> 3. Now put car on axle stands at normal front jacking points. I have also placed a block of wood under the sills just in case!<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeairfilter.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeairfilter.jpg[/img][/url]<br /> <br /> 4. Now open the bonnet and remove the air filter and associated pipe work<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcable.jpg[/img][/url]<br /> <br /> 5. Remove the clutch cable from the clutch lever. At this point it is also worth removing the bolt that holds on the expansion bottle.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcablefrombracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcablefrombracket.jpg[/img][/url]<br /> <br /> 6.Remove the clutch cable from the guide bracket.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg[/img][/url]<br /> <br /> 7. Remove the spring clip from the smaller of the two gear selector cables and pop off the cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcablepin.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcablepin.jpg[/img][/url]<br /> <br /> 8. Remove the spring clip from the larger gear selector cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcable.jpg[/img][/url]<br /> <br /> 9. Pop off the larger gear selector cable from its pin.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removespeedocable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removespeedocable.jpg[/img][/url]<br /> <br /> 10. Remove the speedo cable by removing the 10mm nut and clamp plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearselectorcablebracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearselectorcablebracket.jpg[/img][/url]<br /> <br /> 11. Remove the three bolts that hold on the gear selector cable mounting bracket. This avoids accidently adjusting the cable lengths.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/disconnectreversinglightswitch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/disconnectreversinglightswitch.jpg[/img][/url]<br /> <br /> 12. Disconnect the wiring from the reversing light switch.<br /> <br /> Its now time to work under the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/draingearboxoil.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/draingearboxoil.jpg[/img][/url]<br /> <br /> 13. Drain the gearbox oil by removing the drain plug.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removecaliperandtopballjoint.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removecaliperandtopballjoint.jpg[/img][/url]<br /> <br /> 14. Unbolt the top wishbone ball joint. Take note of how many shims are placed in front of and behind the balljoint. there should be 8 shims in total for each ball joint. In my car there are also inserts to set the camber. Remove the brake caliper and tie it up out of the way. <br /> <br /> The drive shaft nuts can now be removed. <br /> <br /> The nearside drive shaft should be pushed through the hub and then popped or levered out of the gearbox. This can be a fiddle as it is held in place by a snap ring. Do not pull the driveshaft out as this might damage the inner plunge joint.<br /> <br /> The off side drive shaft should be removed by removing the jackshaft bracket bolts then pushing the driveshaft through the hub. The offside driveshaft has no circlip at the gearbox and will slip out easily.<br /> <br /> The drive shafts can be left supported by the suspension yolks but make sure they are not in the way of the gearbox.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronfront.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronfront.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronviewonramp.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronviewonramp.jpg[/img][/url]<br /> <br /> At this point support the gearbox and engine from above or below using a trolley jack.<br /> <br /> I used a bracket to support the engine from above and I placed a trolley jack under the sump. I also put a strap around the gearbox and over the support frame up above.<br /> <br /> 15. Remove the progeron and the front damper along with two of the bellhousing bolts. Start at the front of the car and work your way back.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeexhaustdownpipe.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeexhaustdownpipe.jpg[/img][/url]<br /> <br /> 16. Now remove the exhaust downpipe<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg[/img][/url]<br /> <br /> 17. Remove the four bolts securing the flywheel cover plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removerearenginemountbracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removerearenginemountbracket.jpg[/img][/url]<br /> <br /> <br /> 18. Its time to remove the rear engine mount bracket.<br /> <br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/frontgearboxmount.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/frontgearboxmount.jpg[/img][/url]<br /> <br /> 19. Now remove the gearbox mount. This has several parts, a damper and a couple of L shaped spacer plates.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/finaltopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/finaltopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/anothertopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/anothertopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg[/img][/url]<br /> <br /> 20. the only thing holding the gearbox on now is three bell housing bolts at the top. These are a bit awkward to get to.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg[/img][/url]<br /> <br /> 21. The gearbox can now be pulled free from the engine and lowered to the floor.<br /> <br /> A few things worth considering before putting it all back together.<br /> <br /> It is worth trial fitting the mounts onto the gearbox as you will find you have an awful lot of bits lying around.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg[/img][/url]<br /> <br /> Start with the gearbox mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg[/img][/url]<br /> <br /> Then the rear engine mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignment.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignment.jpg[/img][/url]<br /> <br /> Aligning the box is quite tricky but perseverence will pay off.<br /> <br /> I hope this post will help anyone considering removing their gearbox or changing a clutch on their Elan.</div>

Rip https://wikilec.com/view/File:Gearboxinitialalignment-1-.jpg 2013-10-30T20:44:34Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Gearboxrearenginemounttempfitted-1-.jpg 2013-10-30T20:43:58Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Gearboxnearsidemounttempfitted3-1-.jpg 2013-10-30T20:43:12Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Gearboxnearsidemounttempfitted2-1-.jpg 2013-10-30T20:42:24Z

<p>Rip: </p> <hr /> <div></div>

Rip https://wikilec.com/view/File:Gearboxnearsidemounttempfitted-1-.jpg 2013-10-30T20:41:44Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Gearboxinitialalignmentfrombelow-1-.jpg 2013-10-30T20:41:05Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Anothertopbellhousingbolt-1-.jpg 2013-10-30T20:40:28Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Thirdtopbellhousingboltviewedthroughwheelarch-1-.jpg 2013-10-30T20:39:34Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Finaltopbellhousingbolt-1-.jpg 2013-10-30T20:38:47Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Frontgearboxmount-1-.jpg 2013-10-30T20:38:16Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removerearenginemountbracket-1-.jpg 2013-10-30T20:37:10Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Remove4boltsfromflywheelcoverplate-1-.jpg 2013-10-30T20:36:41Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removeexhaustdownpipe-1-.jpg 2013-10-30T20:36:03Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Prongeronviewonramp-1-.jpg 2013-10-30T20:35:09Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Prongerondamperandbellhousingbolts-1-.jpg 2013-10-30T20:34:24Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Prongeronfront-1-.jpg 2013-10-30T20:33:42Z

<p>Rip: </p> <hr /> <div></div>

Rip https://wikilec.com/view/File:Removecaliperandtopballjoint-1-.jpg 2013-10-30T20:32:28Z

<p>Rip: </p> <hr /> <div></div>

Rip https://wikilec.com/view/File:Draingearboxoil-1-.jpg 2013-10-30T20:31:53Z

<p>Rip: </p> <hr /> <div></div>

Rip https://wikilec.com/view/File:Disconnectreversinglightswitch-1-.jpg 2013-10-30T20:31:12Z

<p>Rip: </p> <hr /> <div></div>

Rip https://wikilec.com/view/File:Removegearselectorcablebracket-1-.jpg 2013-10-30T20:30:30Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removespeedocable-1-.jpg 2013-10-30T20:28:56Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removelargegearselectorcable-1-.jpg 2013-10-30T20:24:30Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removelargegearselectorcablepin-1-.jpg 2013-10-30T20:23:32Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removegearsmallselectorpinandcable-1-.jpg 2013-10-30T20:22:45Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removeclutchcablefrombracket-1-.jpg 2013-10-30T20:21:56Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removeclutchcable-1-.jpg 2013-10-30T20:19:02Z

<p>Rip: Gearbox removal</p> <hr /> <div>Gearbox removal</div>

Rip https://wikilec.com/view/File:Removeairfilter-1-.jpg 2013-10-30T20:18:26Z

<p>Rip: Gearbox removal procedure</p> <hr /> <div>Gearbox removal procedure</div>

Rip https://wikilec.com/view/File:Supportonaxlestands-1.jpg 2013-10-30T20:09:14Z

<p>Rip: Gearbox removal procedure</p> <hr /> <div>Gearbox removal procedure</div>

Rip https://wikilec.com/view/File:Removewheel-1-.jpg 2013-10-30T20:07:13Z

<p>Rip: Gearbox removal procedure</p> <hr /> <div>Gearbox removal procedure</div>

Rip https://wikilec.com/view/Gearbox_removal 2013-10-25T20:46:28Z

<p>Rip: </p> <hr /> <div>[http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/loosendriveshaftnuts.jpg]<br /> <br /> 1. Start by jacking up car, removing front wheels, pop out wheel centres, put wheels back on and loosen drive shaft nuts.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removewheel.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removewheel.jpg[/img][/url]<br /> <br /> 2. Jack up car, remove front wheel, place another jack at the inner jacking point at the rear of the prongeron and raise the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/supportonaxlestands.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/supportonaxlestands.jpg[/img][/url]<br /> <br /> 3. Now put car on axle stands at normal front jacking points. I have also placed a block of wood under the sills just in case!<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeairfilter.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeairfilter.jpg[/img][/url]<br /> <br /> 4. Now open the bonnet and remove the air filter and associated pipe work<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcable.jpg[/img][/url]<br /> <br /> 5. Remove the clutch cable from the clutch lever. At this point it is also worth removing the bolt that holds on the expansion bottle.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcablefrombracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcablefrombracket.jpg[/img][/url]<br /> <br /> 6.Remove the clutch cable from the guide bracket.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg[/img][/url]<br /> <br /> 7. Remove the spring clip from the smaller of the two gear selector cables and pop off the cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcablepin.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcablepin.jpg[/img][/url]<br /> <br /> 8. Remove the spring clip from the larger gear selector cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcable.jpg[/img][/url]<br /> <br /> 9. Pop off the larger gear selector cable from its pin.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removespeedocable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removespeedocable.jpg[/img][/url]<br /> <br /> 10. Remove the speedo cable by removing the 10mm nut and clamp plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearselectorcablebracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearselectorcablebracket.jpg[/img][/url]<br /> <br /> 11. Remove the three bolts that hold on the gear selector cable mounting bracket. This avoids accidently adjusting the cable lengths.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/disconnectreversinglightswitch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/disconnectreversinglightswitch.jpg[/img][/url]<br /> <br /> 12. Disconnect the wiring from the reversing light switch.<br /> <br /> Its now time to work under the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/draingearboxoil.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/draingearboxoil.jpg[/img][/url]<br /> <br /> 13. Drain the gearbox oil by removing the drain plug.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removecaliperandtopballjoint.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removecaliperandtopballjoint.jpg[/img][/url]<br /> <br /> 14. Unbolt the top wishbone ball joint. Take note of how many shims are placed in front of and behind the balljoint. there should be 8 shims in total for each ball joint. In my car there are also inserts to set the camber. Remove the brake caliper and tie it up out of the way. <br /> <br /> The drive shaft nuts can now be removed. <br /> <br /> The nearside drive shaft should be pushed through the hub and then popped or levered out of the gearbox. This can be a fiddle as it is held in place by a snap ring. Do not pull the driveshaft out as this might damage the inner plunge joint.<br /> <br /> The off side drive shaft should be removed by removing the jackshaft bracket bolts then pushing the driveshaft through the hub. The offside driveshaft has no circlip at the gearbox and will slip out easily.<br /> <br /> The drive shafts can be left supported by the suspension yolks but make sure they are not in the way of the gearbox.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronfront.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronfront.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronviewonramp.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronviewonramp.jpg[/img][/url]<br /> <br /> At this point support the gearbox and engine from above or below using a trolley jack.<br /> <br /> I used a bracket to support the engine from above and I placed a trolley jack under the sump. I also put a strap around the gearbox and over the support frame up above.<br /> <br /> 15. Remove the progeron and the front damper along with two of the bellhousing bolts. Start at the front of the car and work your way back.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeexhaustdownpipe.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeexhaustdownpipe.jpg[/img][/url]<br /> <br /> 16. Now remove the exhaust downpipe<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg[/img][/url]<br /> <br /> 17. Remove the four bolts securing the flywheel cover plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removerearenginemountbracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removerearenginemountbracket.jpg[/img][/url]<br /> <br /> <br /> 18. Its time to remove the rear engine mount bracket.<br /> <br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/frontgearboxmount.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/frontgearboxmount.jpg[/img][/url]<br /> <br /> 19. Now remove the gearbox mount. This has several parts, a damper and a couple of L shaped spacer plates.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/finaltopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/finaltopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/anothertopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/anothertopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg[/img][/url]<br /> <br /> 20. the only thing holding the gearbox on now is three bell housing bolts at the top. These are a bit awkward to get to.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg[/img][/url]<br /> <br /> 21. The gearbox can now be pulled free from the engine and lowered to the floor.<br /> <br /> A few things worth considering before putting it all back together.<br /> <br /> It is worth trial fitting the mounts onto the gearbox as you will find you have an awful lot of bits lying around.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg[/img][/url]<br /> <br /> Start with the gearbox mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg[/img][/url]<br /> <br /> Then the rear engine mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignment.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignment.jpg[/img][/url]<br /> <br /> Aligning the box is quite tricky but perseverence will pay off.<br /> <br /> I hope this post will help anyone considering removing their gearbox or changing a clutch on their Elan.</div>

Rip https://wikilec.com/view/Gearbox_removal 2013-10-25T20:30:14Z

<p>Rip: </p> <hr /> <div>[image:http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/loosendriveshaftnuts.jpg]<br /> <br /> 1. Start by jacking up car, removing front wheels, pop out wheel centres, put wheels back on and loosen drive shaft nuts.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removewheel.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removewheel.jpg[/img][/url]<br /> <br /> 2. Jack up car, remove front wheel, place another jack at the inner jacking point at the rear of the prongeron and raise the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/supportonaxlestands.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/supportonaxlestands.jpg[/img][/url]<br /> <br /> 3. Now put car on axle stands at normal front jacking points. I have also placed a block of wood under the sills just in case!<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeairfilter.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeairfilter.jpg[/img][/url]<br /> <br /> 4. Now open the bonnet and remove the air filter and associated pipe work<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcable.jpg[/img][/url]<br /> <br /> 5. Remove the clutch cable from the clutch lever. At this point it is also worth removing the bolt that holds on the expansion bottle.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeclutchcablefrombracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeclutchcablefrombracket.jpg[/img][/url]<br /> <br /> 6.Remove the clutch cable from the guide bracket.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearsmallselectorpinandcable.jpg[/img][/url]<br /> <br /> 7. Remove the spring clip from the smaller of the two gear selector cables and pop off the cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcablepin.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcablepin.jpg[/img][/url]<br /> <br /> 8. Remove the spring clip from the larger gear selector cable.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removelargegearselectorcable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removelargegearselectorcable.jpg[/img][/url]<br /> <br /> 9. Pop off the larger gear selector cable from its pin.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removespeedocable.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removespeedocable.jpg[/img][/url]<br /> <br /> 10. Remove the speedo cable by removing the 10mm nut and clamp plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removegearselectorcablebracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removegearselectorcablebracket.jpg[/img][/url]<br /> <br /> 11. Remove the three bolts that hold on the gear selector cable mounting bracket. This avoids accidently adjusting the cable lengths.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/disconnectreversinglightswitch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/disconnectreversinglightswitch.jpg[/img][/url]<br /> <br /> 12. Disconnect the wiring from the reversing light switch.<br /> <br /> Its now time to work under the car.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/draingearboxoil.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/draingearboxoil.jpg[/img][/url]<br /> <br /> 13. Drain the gearbox oil by removing the drain plug.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removecaliperandtopballjoint.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removecaliperandtopballjoint.jpg[/img][/url]<br /> <br /> 14. Unbolt the top wishbone ball joint. Take note of how many shims are placed in front of and behind the balljoint. there should be 8 shims in total for each ball joint. In my car there are also inserts to set the camber. Remove the brake caliper and tie it up out of the way. <br /> <br /> The drive shaft nuts can now be removed. <br /> <br /> The nearside drive shaft should be pushed through the hub and then popped or levered out of the gearbox. This can be a fiddle as it is held in place by a snap ring. Do not pull the driveshaft out as this might damage the inner plunge joint.<br /> <br /> The off side drive shaft should be removed by removing the jackshaft bracket bolts then pushing the driveshaft through the hub. The offside driveshaft has no circlip at the gearbox and will slip out easily.<br /> <br /> The drive shafts can be left supported by the suspension yolks but make sure they are not in the way of the gearbox.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronfront.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronfront.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongerondamperandbellhousingbolts.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/prongeronviewonramp.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/prongeronviewonramp.jpg[/img][/url]<br /> <br /> At this point support the gearbox and engine from above or below using a trolley jack.<br /> <br /> I used a bracket to support the engine from above and I placed a trolley jack under the sump. I also put a strap around the gearbox and over the support frame up above.<br /> <br /> 15. Remove the progeron and the front damper along with two of the bellhousing bolts. Start at the front of the car and work your way back.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removeexhaustdownpipe.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removeexhaustdownpipe.jpg[/img][/url]<br /> <br /> 16. Now remove the exhaust downpipe<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/remove4boltsfromflywheelcoverplate.jpg[/img][/url]<br /> <br /> 17. Remove the four bolts securing the flywheel cover plate.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/removerearenginemountbracket.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/removerearenginemountbracket.jpg[/img][/url]<br /> <br /> <br /> 18. Its time to remove the rear engine mount bracket.<br /> <br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/frontgearboxmount.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/frontgearboxmount.jpg[/img][/url]<br /> <br /> 19. Now remove the gearbox mount. This has several parts, a damper and a couple of L shaped spacer plates.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/finaltopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/finaltopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/thirdtopbellhousingboltviewedthroughwheelarch.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/anothertopbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/anothertopbellhousingbolt.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gettingtoanotherbellhousingbolt.jpg[/img][/url]<br /> <br /> 20. the only thing holding the gearbox on now is three bell housing bolts at the top. These are a bit awkward to get to.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignmentfrombelow.jpg[/img][/url]<br /> <br /> 21. The gearbox can now be pulled free from the engine and lowered to the floor.<br /> <br /> A few things worth considering before putting it all back together.<br /> <br /> It is worth trial fitting the mounts onto the gearbox as you will find you have an awful lot of bits lying around.<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted2.jpg[/img][/url]<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxnearsidemounttempfitted3.jpg[/img][/url]<br /> <br /> Start with the gearbox mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxrearenginemounttempfitted.jpg[/img][/url]<br /> <br /> Then the rear engine mount<br /> <br /> [url=http://s183.photobucket.com/user/headit/media/Elan%20Gearbox/gearboxinitialalignment.jpg.html][img]http://i183.photobucket.com/albums/x156/headit/Elan%20Gearbox/gearboxinitialalignment.jpg[/img][/url]<br /> <br /> Aligning the box is quite tricky but perseverence will pay off.<br /> <br /> I hope this post will help anyone considering removing their gearbox or changing a clutch on their Elan.</div>

Rip