DIY new clutch Elite '77, can I do it?

[CharlieCroker]

Hi Guys,

 

My Elite arrives next Wednesday and I already know it needs a new clutch. Question is, can I do it myself is it a DIY job or not bother and let the pro's have it?

 

Thanks, Charlie ;-)

[Dunc]

kind of depends on your skills with the spanners Charlie..... whats DIY to some would frighten others.

[CharlieCroker]

Im not too bad, just don't have facility to raise the car other than axle stands. There will be several jobs to do so once I get the car, so was hoping to do as much as I can myself. I don't mind grazing my knuckles once or twice! ;-)

[Herc]

Charlie, see http://www.thelotusforums.com/forums/topic/44208-clutch-replacement/?hl=%2Breplace+%2Bclutch.

 

If you aren't familiar with these cars, the added excitement when changing clutch is that you can't take the gearbox 'out backwards' like you can on most rear drive cars.  This is because it nestles in the fork of the chassis.  Hence you have to remove the engine first.  

 

It's not a hi-tech job though - very little in the Elite seems to be, really.  Watch out that the long bonnet means you really need a long-reach engine hoist. 

 

Herc

[mikeeech]

long reach enginer hoist sounds like a top tip! my engine is ready to pull out so can't be too hard.

with the exception of clutch cable,

exhaust

power steering pump.

the only difficut thing is getting the sodding exhaust off! buts thats so true in all cases of removing rusty bolts! makes mental note;- need to get stainless steel replacements...

[Herc]

Mike

 

Contrary to some of the advice on the forum, I took the engine and gearbox out  in one piece, as the manual suggests.  I found it hard to get stop the engine swinging forward into the bodywork.  I would recommend getting your straps in a well balanced spot (some advice on previous posts) and unbolting the gearbox.

 

Cheers

Herc

[CharlieCroker]

Sounds like fun! I can just imagine getting as far as pulling the engine, only for it to swing back and destroy either the front end or make a nice hole in the windscreen! I may get the pro's to do it as I my home garage is not the best equipped and I generally work on my own. Thanks :-) What sort of money would a garage charge to replace it? 

Edited February 17, 2014 by CharlieCroker

[johnpwalsh]

Hi and welcome, I have done ths job several times now and can give you the following tips.

 

N0 1/ remember and select 2nd or 4th gear before removing the gear leaver from the gearbox or you wont get it back in.

 

No 2/ when removing the front exhaust pipe from the manifold remove the rubber exhaust hangers so the the exhaust sags down a bit, this lets you in a bit easier to get at the most awkard nut.

 

N0 3/ when replacing the engine and box have someone under the car to guide the propshaft back into the tailshaft of the gearbox and be careful you dont trap your fingers, it's a bloody sharp edge as I know to my cost.

 

I purchased a 2 tonne engine crane off ebay and had it extended at a local old school blacksmiths so that I would have the reach as I also needed if for my Esprit.

 

Complete task took me about 4 hrs, the worst was getting the bolts at the back of the cylinderheard on the bell housing as they were tight as hell.

 

Once completed go have a beer it's well deserved.

Edited February 17, 2014 by johnpwalsh

[eclat22]

I use an engine load leveller available from machine mart, this makes the whole job far easier as you can adjust the angle of the engine and gearbox. Again I have access to an engine lift that has had en extended arm made for it.

Regards Dan

[Denis247]

It's possible to replace clutch without removing engine.  My first clutch renewal was done this way.

Edited February 17, 2014 by Denis247

[johnpwalsh]

Hi Dan, agree with you, a load leveler is my next purchase, I used two ratchet straps last time to tilt the engine, not the best but it worked but you had to be oh so careful. I also have a near new clutch assembly, fitted to my old engine then did less than 1,000 miles.

Edited February 17, 2014 by johnpwalsh

[CharlieCroker]

Will this lift be long enough?

 

http://www.ebay.co.uk/itm/161229147618?ssPageName=STRK:MEWAX:VRI&_trksid=p3984.m1423.l2661

 

Thanks :-)

[johnpwalsh]

Yep thats the same as the one I purchased, but as I said I had a new arm made for it which was a good 2ft longer than the original. What I have to do with mine is I jack the car up and put a couple of bricks under the front wheels, this gives enough height to get the crane underneath Can I suggest you do a dummy run just with the crane to measure the reach then take a measurement from the the end of the crane, not the extending piece but the box section that it slides into, Then take that measurement plus half the length of the boom and that is the length of new extended arm you will need. If you have it made out of box section steel get it in a smaller size so thet you can then have a length of angle iron welded onto each side for added strength. I can send you pics of my one if you forward your email address to to me as I am having problems with getting attachments on the tlf site.

 

John.

[mdw]

Yep same as mine however as with others I have extended the arm. We simply slid a scaffold pole all the way down the arm and welded a 1/2" thick plate on the end with a bolt hole for the leveller.  Obviously be careful  as you may need to extend the legs as well or have a fat bloke standing on the jacking end  when you use it.

[CharlieCroker]

It's possible to replace clutch without removing engine.  My first clutch renewal was done this way.

Would you like to elaborate on how you did it without removing the engine? Thanks

[Denis247]

Would you like to elaborate on how you did it without removing the engine? Thanks

My first clutch started slipping just after getting the car way back in 1979, and I just put it into a firm called "The Clutch Centre" here in London.

 

I'm not sure if they're still going, but they replaced the clutch with the engine in-situ.  So it must be possible.

 

The only times that I myself have changed clutches are when I've had gearbox problems, first with the Lotus engine then later with the Rover, and of course then I removed the whole unit.

[CharlieCroker]

While we are talking about the clutch, can I ask another question? The gear lever I noticed is very sloppy, can it be adjusted whilst in the car or does the box have to come out? Thanks.

[Herc]

Charlie

i assume you have a Lotus ('Maxi') 5 speed?

 

There is a funny little plastic saddle that sits at the bottom of the gearlever.  You can see a picture of this if you go to http://www.sjsportscars.co.uk  and search for part number  SJ075F0009.  The corners break off this and result in very vague gearshifting.  I had this problem and changing this bit of plastic made all the difference. The shift is very light by design, but reasonably precise when in good condition.

 

I would recommend having a look at this first since you just need to remove the gear stick - you can do it with the gearbox in-place.  I say 'just remove' - it can be a bit knuckle scraping!  Also make sure you put the car into 3rd or 4th first, to "prevent ball and socket joint from disengaging".

 

If you haven't got a workshop manual, I would heartily recommend getting one ASAP.  It is very useful indeed, and a marvellous piece of pre-Desktop Publishing layout to boot.   eBay is a good source for used manuals.  They tend to go for up to £50.  The parts manual is cheaper, but less useful.    There is often a CD of the manual floating around on eBay - this is a) a pirate production  b) rubbish quality photocopying.    I believe you can get new manuals still from Lotus?

 

Herc

[CharlieCroker]

Cheers Herc, great information and I do have the manual, came with the car, a must have me thinks! Ok so this weekend I start to disconnect everything from the engine to remove the lump. Is there an itinerary to remove the engine that I should adhere to to save time and more importantly grazed knuckles!  

[CharlieCroker]

Also, what clutch kit do I need, do I go for the full 3 piece kit i.e, plate, bearing and friction plate or will I just need to swap the friction plate? And where do I find the best deal, SJS or LotusBits or independent? 

[Herc]

Personally I shop around.  Best prices usually vary from item to item.  LotusBits are usually pretty cheap, but limited on range, and you need to telephone them - emails rarely work.

 

If it were my clutch, with unknown provenance, and needing the engine out, I'd lean toward change the lot unless anything was unduly expensive.  But that's not based on any specific experience of these gearboxes.  The cables are prone to snapping, so that might be worth doing at the same time.

 

For engine parts I find Kemp performance engines on eBay quite useful too.   If you are into your prepp'ing, they do a very nice kit of stainless bolts for the whole engine. 

 

If you search the forum there are some existing posts about removing the engine and where to strap the engine.

 

Herc

Edited February 28, 2014 by Herc

[CharlieCroker]

I've srarted taking off ancillaries to the engine and have removed everything except the PAS pipes. Can anyone advise me how I sholud proceed so not to make a mess with steering fluid, is it a case of just releasing the pipe that goes to the block, will fluid flow out? Thank, Charlie :-)

[johnpwalsh]

How you getting on Charlie, when removing the ppower steering pipes I did mine, one from the pump and the second from the steering box on the near side, be prepaired for corroded fitting on this end though, I had a local hydraulis hose supplier make me up a new set using s/s pipes for under forty quid, perfect. Once you re assemble all you have to do is get the fron of the car up on a jack, have someone turn the steering back and forth and refill with fresh oil, this gets rid of the air in the system, then just keep an eye on the level for a while.

[CharlieCroker]

All going well thanks, I've been set back a touch with a body alignment issue that I am currently trying to put right so I'm now a couple of months back to where I wanted to be, never the less mostly going to plan and changing the clutch is definitely a job in the realms of any DIY mechanic. So glad I opted to do it myself as the rear crank shaft seal needed replacing, now I KNOW it is done. 

 

Edited April 7, 2014 by CharlieCroker

[mikeeech]

Charlie...do you have any pictures of your new clutch plate? Odd question perhaps but I have removed mine finally and its a bit thin but looks repainted!