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HELP! 24k miles - clutch drops to floor 2010 Evora S1


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I've a 2010 NA and this has just happened to me... 10miles from home, spent 15minutes in a queue of traffic, so stop/start, lots of clutch work etc.. and I lost the clutch pedal to the floor and couldn't engage 1st or 2nd gears. After a mild panic and I don't know whether it just came up by itself or my foot inadvertently lifted the pedal, the pedal came back and all was well and normal and has been since. Looking through this thread and others it seems there are a number of solutions, i.e. heat wrapping the slave cylinder pipe, higher spec fluid and replacing the master cylinder. So I know what I'm dealing with can anyone help with the following:

1. From the attached photo, can anyone tell me whether I have the metal bodied master cylinder that was apparently fitted to my age of car, or whether this is the replacement plastic one. Al lI can see protruding into the foot well is the black top and I'm not sure whether its metal or plastic behind this. I have nothing in any receipts that tell me any work has been done.

2. I've noticed there is wet around the seal and on the push rod.. is this telling me the seal is gone or is it normal to have some wetness?

3. Do I need to take the rear under panel off to see whether my slave cylinder pipe has already been wrapped or am I able to see it from above. I've had a quick look and I'm not really sure where I should be looking and I can't see much?

4. For those who have experienced this, is this an asap job to get done or did you wait for your next service. I'm thinking the former as the car is still under warranty which may cover this?

Any help much appreciated,

Ade

 

MC2 smaller.jpg

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The symptoms sounds exactly like my car that needed a new master cylinder for the clutch.

Not an expert but don't think there should be any wetness on the push rod of the master or slave on a hydraulic system.  The seals should be preventing any liquid from escaping.

I think in a standard car the air box is in the way and you can't see the slave cylinder from the top.  You might be able to hold a phone while recording a video and get it down into position to see the cylinder then examine the video afterwards.  If you search on Lotus Talk forum there are some great guides on clutch fluid changes etc that should be able to help you out with location and getting access to it.

Clutch replacement is £2000-£4000 and you could be doing damage with it not working correctly and accelerating the wear rate.  It don't think there is any harm in letting the car sit for some time and then getting the work done but it's probably not great to carry on putting lots of miles on it.  

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1 hour ago, electro_boy said:

I think in a standard car the air box is in the way and you can't see the slave cylinder from the top.  You might be able to hold a phone while recording a video and get it down into position to see the cylinder then examine the video afterwards.  If you search on Lotus Talk forum there are some great guides on clutch fluid changes etc that should be able to help you out with location and getting access to it.

Thanks for this, may give that a go....

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I was able to drive for several months with it playing up - I think the pedal went funny a couple of times before it went in to be fixed. I might have been lucky.

I always take the car out of gear and release the pedal when sat at a junction for more than a few seconds. 

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It's rather inconsistent when the pedal goes limp, so it could actually be a safety issue depending on when it happens. Mine decided to drop to the floor while on a banked on-ramp, merging with 2 other lanes of traffic. Tried to downshift, and nada. Imagine diving into a corner at high speed, expecting to be able to slow and downshift prior, only to be stuck in your current gear. Sure the brakes should still work (hopefully!), but it would be unsettling at the bare minimum.

I say get it addressed sooner than later, and drive cautiously in the meantime. 

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If I my throw in a thought, there is a valve in the piston that may not seat and allow the clutch fluid to just by pass the piston, this is often a symptom of rubbish in the fluid, indicating a lack of service.

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As I understand it (my pedal suffered the same a few years ago), the engine will cook the fluid in the clutch line due to its proximity.

Definitely worth wrapping (re-wrapping?) the clutch pipes if this hasn't been done already, higher spec fluid is a good idea, as is completely flushing both the brake/clutch lines annually. The lack of cooling in the S1 probably doesn't help when you're stuck in stop/start traffic.

It's a shame things like https://www.boefab.com/collections/evora/products/evora-cooling-tray aren't available (cost-effectively) in the UK.

Edited by trcm
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Are there any early warning signs of master cylinder failure? I'm not convinced my clutch isnt cleanly dissenagaging all the time as the gears can be a bit baulky to engage. I've bled the clutch and wrapped the slave cylinder pipe but no major improvement. Or is it just the Auris derived box is agricultural ?

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  • 2 weeks later...

So decided to have go at improving the clutch action ... Only did the slave cylinder for now as I didn't fancy doing a front end off job just yet ... It's flippin hard to get at . Found out it wasn't heat wrapped , so that's done  and new slave cylinder is in but there must be a specialist multi elbowed mechanics arm in the lotus specialised tools list !

PSX_20210328_191201.thumb.jpg.8070945436e5f7da6ef2e2512c7314e6.jpg

That's before I managed to swap the cylinder but with the shiney heat wrap in place The car has had a new clutch and gearbox rebuild in its recent history , I can't believe for the cost the slave cylinder it wasn't swapped at the time. The clutch action feels better but I can't work out if that's just in my head after a weekend swearing.

WIll get a master cylinder on order just for peace of mind and have on the shelf incase I decide to take the front clam off in the near future.

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Did the exact same job this weekend!! Zip tied a fire sleeve round the slave cylinder pipe.. bit of a mission from below. Did you replace the slave cylinder from below or above? I'd be interested in how you get on replacing the master cylinder when you get round to it...

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4 hours ago, AdeMorton said:

Did the exact same job this weekend!! Zip tied a fire sleeve round the slave cylinder pipe.. bit of a mission from below. Did you replace the slave cylinder from below or above? I'd be interested in how you get on replacing the master cylinder when you get round to it...

From below as per the instruction manual... Just "from underneath the car, undo and plug the hydraulic pipe from the slave cylinder and remove the 2 mounting bolts...re fitting is the reverse of removal " FFS one shredded arm and a lost weekend later !

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Yep, thanks for this... I thought that would be the case.. and was my plan B if from below was too tricky. Whilst being fiddley it was doable, that being the heat wrap part anyway. I didn't replace the slave cylinder.. want to see if I have any more problems before thinking about replacing the master cylinder.

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  • 7 months later...

Lotus never admitted there was an issue w/ the clutch mc, aside from the revision between MY11-12, when they switched from an all-metal one to an all-plastic one. Either way, they're not very reliable parts, and overheating the fluid can't help in any situation. 

I would highly recommend changing out whichever OE mc is there with either a Wilwood or Tilton, as they're much more reliable, and can be rebuilt from the pedal side. 

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