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Esprit Turbo project car - part3 - the further continuation - Page 173 - Esprit 'Project & Restoration' Room - The Lotus Forums Jump to content
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Esprit Turbo project car - part3 - the further continuation

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Well there is a kind of magic going on here, but not in a positive way! Somehow the gears reordered themselves! Still no harm done I realised and was easily able to reorder them correctly using the manual and my pictures. I have the pinion shaft and reverse gear back in. I may have to dismantle it again to get the rest in, but so far so good. If I did this again it would be much easier. But I have to say if I lived near the Wirral I would have taken it to Alan Voigts. If I live near Harry I would have taken it to him. It would have been much quicker! Putting it back together will not be difficult but the real test will be how it performs and how many years it lasts. I've got a feeling longevity will not be a problem at my age! In a weird way it's nice to do something different, I always like a challenge especially when I'm told I can't do it! 

IMG_7242.thumb.JPG.ce8f0e3c938d82a416e7863f705e7f48.JPGSo far,  new bearing in. May have to partially remove it again -  we'll see.

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TBH gearboxes are specialist things and unless you're keen to learn, or short of funds, they're best left alone IMO.

Voigts were helpful when I had my S1 gearbox/transaxel done. Though I had mine done by a transmission specialist near me. With me supplying parts, including the "Citroen" tool, which they machined down to fit.

Having road tested it last week it seems to work thankfully! It was rebuilt in 2017.

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I don't disagree. I've been messing around with this for a few weeks now. I am able to spend as much time  on it as required to get a good result. I already understand it pretty well. However,  go and get a specialist they'll do a great job and it will work! I've started so I'm  going to rebuild it to the highest standard I can.

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The only thing I did in relation to my gearbox was replace the circlip which had rusted out. Other than that I changed the oil and it's been fine ever since. If it ain't broke, don't fix it!

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Lotus Esprit [meaning] a 1:1 scale Airfix kit with a propensity to catch fire

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Well, you know me Paul - it all has to come apart! 

To be fair, it's a pretty simple gearbox. 

I'm now just about to remove the shafts again, drop the piñon gears down and install the primary shaft. Just wanted to see how it all fits. Ohh and of course I will measure the pinion height, as I have replaced the pinion bearing.

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You're a brave man Fabian!

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Brace or foolish, the two are quite closely linked!  Anyhow .....IMG_7250.thumb.JPG.2bad642e1640399fb5ee5f40bb6ff24e.JPGthey are back in! New bearings and third gear with synchro. Now just have to wait for some parts - two weeks forvtge seals! 

IMG_7249.JPG

Now the rest of it! 

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I really like the design of that Citroen box. Its much neater than other transaxles such as the Renault or Hewland etc. Makes you wonder why they are not all designed that way.

Probably stronger than the clam shell design of the others as well.

 

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IMG_7252.thumb.JPG.a9cebd004879d8f7778cf0a26abed948.JPGPinion height measured using a vernier and straight edge. Consistent with the engraved figure. No reaso it should have changed. Speedo gear back on. Loctite used. Now the rear casing, can't find in the manual any use of sealant or gasket. It was sealed with silicon when I took it apart. More research job halted.

 

Disregard, found the reference to sealing all mating faces!

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This is the best stuff to use

DSCN3748.JPG

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Definitely seal the rear casing.

The advice to use the full 3L of lubricant will fill the rear casing, which I was told is the OD section. The sealant will stop anything dripping.

I was told it is technically speaking, an OD, rather than a 5th gear. Hence OD on the gear knob. It's certainly not like my old Laycock OD unit!

Edited by Fridge

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Its a conevntional gear and synchro just like all the other gears but you could define it as an overdrive as the ratio is pretty high.

I have not managed to overcome the problem of oil being pumped out the speedo drive. This happens as the box is being driven backwards, if anyone has fixed this I would be interested. There is no oil seal on the drive.

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I found Loctite 518, which I had ordered and forgot about. So plan to use that. I have lost two of the housing bolts! They are two different lengths. Getting this bit wrong is not an option as the bolts pass through the case. Two long and they will fouls the gears. So far ithis job has been pretty straight forward. I will need to address the issue of the speedo gear oil leak as I intend to use 3 L of Redline in this box. I will examine the fixture as I have it out. Silicon sealant?

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Maybe, but my transmission specialist says it is "technically an OD". He's the expert. That's all they do. Motorcycles, cars, vans, right up to dragsters!

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5 minutes ago, Fridge said:

Maybe, but my transmission specialist says it is "technically an OD". He's the expert. That's all they do. Motorcycles, cars, vans, right up to dragsters!

I would be interested to know his reasoning. In the box its just another gear, with an extra selector shaft, actuated by the same selector levers as the other shafts. Same type of synchro. 

Its no different to the 5th in any other 5 speed box.

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I would think so too Andy. As I'm used to separate OD units bolted onto 4-speed gearboxes.

He said this is essentially a secondary casement. Hence the OD marking on the gear knob being so marked.

Like I said, he's a transmission expert.

Unfortunately that work is done. The box seems to work, having had it on the road briefly last week. The transmission was completely rebuilt in early 2017. I'd have to make a special visit to see him. Though not far away.

It would be interesting to hear what Voigts or Harry Martins have to say.

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Ok the end housing bolts are M9 and the end case are M7. Anyone found a good supplier? 

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43 minutes ago, Fridge said:

Hence the OD marking on the gear knob being so marked.

 

The wooden gear knob with OD marked came I believe from the Elan S130/5. They continued it into the Esprit. Not sure exactly what gearbox that had. 

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Top gear is 'overdriven' in so far as the output shafts turn more than 1 revolution for  each revolution of the input shaft in 5th (and  marginally  in 4th) - Most 'classic' gearboxes would traditioanlly have a direct 1:1 ratio top gear.  Of course, its not an overdrive in the same way that its an extra 2 speed gearbox strapped onto the back of a conventional gearbox like a Laycock unit.   

A good Bolt & Nut stockist or engineering supplier may well provide 7mm/9mm from stock.  

 

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Yup! I sold a NOS one for about £145 last year.

Thanks for the clarity @910Esprit sounds likely.

Edited by Fridge
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17 minutes ago, 910Esprit said:

Top gear is 'overdriven' in so far as the output shafts turn more than 1 revolution for  each revolution of the input shaft in 5th (and  marginally  in 4th) - Most 'classic' gearboxes would traditioanlly have a direct 1:1 ratio top gear.  Of course, its not an overdrive in the same way that its an extra 2 speed gearbox strapped onto the back of a conventional gearbox like a Laycock unit.   

A good Bolt & Nut stockist or engineering supplier may well provide 7mm/9mm from stock.  

 

I've had a good look, very limited sizes. Usual suspects very expensive.

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I will be refitting the selector forks. Before I took them out I marked the fork positions with engineering blue. I need to check they are correct. Has anyone got any Lotus synchro gauges? If not no probs I will improvise.

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Well I have test fitted the selectors. It took a lot of cleaning and polishing to get them to move perfectly. I've lost two of the locking grub bolts! No surprise there! I need to set the fork positions before any of it can be finalised and wire locked. I thought to my self I could get my local gearbox place to set the synchros as they would have gauges, but that would be cheating!  All pretty straight forward so far. I shall test all of the gear operation by rotating the shafts by hand. I also need so 9 mm bolts😩😩😩Would be much cheaper if I hadn't lost 10 percent if this car! I blame it on a tiny garage. You need a double or preferably triple fir this sort of resto. I glanced around and noticed the parts have gone down a lot, that has to be good IMG_7261.thumb.JPG.42db824bb9c42d3be44c241aab8bbef2.JPGnews.  This isn't final fix, I'm triple checking everything before that. I have cleaned the corrosion on the selectors. Just wondering whether to coat or leave them as is?

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I usually have the opposite problem ie parts left over :)  Lost tools though, mostly down the black holes which are either sides of the fuel tanks.

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