Easy Access To The Diff.

[RotoFlexible]

Just a thought but are the frequent diff top-ups specified in the manual really necessary - especially so with the improvement in lubricants since the car was designed? Frequent diff up-topping doesn't seem to feature in other cars' requirements.

I think the problem isn't that the lube goes bad but rather that it doesn't stay in the diff. If modern seals are more effective, perhaps the checking interval can be extended.

[ceejay]

The diff level should be checked at normal service intervals, the more easy the access is the more likely that the job will get done. If you ever experienced a diff running out of oil while driving you will want to frequently check the oil level. I once had a diff out-put shaft seal blow while returning from the far south coast of NSW here in OZ, it happened while hammering down a mountain pass when all hell broke loose, the sound of a diff about to seize plus the smell of a hot diff is not something I want to see or hear or smell again. That's why I then made it easy to access from inside the boot.... just to spend a few minutes checking. It's no big deal, but you just want to be certain that all is OK before heading off for a blast on your favourite driving road.

[garyeanderson]

Like most subjects that come up on the forum this appears to have been coversed before,

http://www.lotuselan.net/publish/differ ... ling.shtml

Gary

[elansprint71]

I've got the access hatch for the diff and also the gearbox.... what can I chop up next??

How about cutting in a moon roof on your FHC?

Gary
'71 Elan Sprint FHC
Miami, FL


Hey, I just got my third gear! Happy New Year!

Happy New Gear!

Someone already cut the roof off my car.

Pete.

[archigator]

I weighed the options, and decided that differential oil access trumps differed maintenance... so I got out the drill. I purchased a 4-inch plastic access hatch for about $18.00 from West Marine, and cut the hole just above and a little to the left of the battery grounding point. It fits perfectly, and I think provides a clean access point to the differential filler plug.

Otherwise, when not being accessed, it's hidden by the spare tire (tyre) and the trunk (boot) wooden panel and carpet. I may have just eliminated myself from the winner's podium at Pebble Beach, but life is full of compromises...

Gary
'71 Elan Sprint FHC
Miami, Florida

[Jason1]

Hi

I like the idea of this access panel, a very neat job at a very reasonable price. I had a quick look on Ebay and for the UK I can get a 4" one for ?3.87 including postage, that is a bargin!!!

Jason

[Barney]

Gary,
Smart job , it looks like a metal finish, is it chromed plastic?
I can't see it in your pictures, but can you also access the handbrake tree to give that a bit of TLC too?

Barney

[ceejay]

There you go fella's, I reckon the diff access/servicing problem has been solved, there's gonna be a lot more servicing done in the near future with all of these quick access holes.... a damn side better than what you had to do previously.

Good on ya.
Col.

[garyeanderson]

these need a 3 1/2 inch hole but they have a lotus part number

[archigator]

It's black plastic. I think it also adds some rigidity and provides a smooth finish when open so your hand doesn't get that abrasive fiberglass edge treatment. You can feel the handbrake workings just beneath the hole.

Gary
'71 Elan Sprint RHD
Miami, Florida

[bloodknock]

Hi Gary,
Imitation is the sicerest form of copying!
Hole ready for marine inspection plate, its going to be fun fitting the inspection plate ring.....those screws ...reaching the nuts to tighten.
Regards
Bob

[ericbushby]

Hi bob,
A few of us in the northwest branch of Club Lotus did a similar mod. some time ago.
We found the fibreglass a bit flimsy and distorted at that point.
By fitting a 3mm sheet aluminium backing ring with tapped holes it held it all straight and meant no nuts were needed.
Eric in Burnley
S3SE DHC

[bloodknock]

Hello Eric
that sounds like a plan, thanks, i'll get straight onto it. though I have to say that GRP I cut through varied from 3 to 5mm thick, but I agree that the surface is not exactly level.
Thanks again
regards
Bob

[steve lyle]

A thank you to all who've come before.

I finally got the urge to change all the fluids on the car, and ran into the problem of accessing the diff fill plug. A few search attempts found the solution.

Here's my implementation.

Thanks,
Steve