Transmission Removal

[Ianashdown]

Is it possible to remove the gearbox from an S2 Elan by lowering it once the engine is removed?

The gear lever on mine is seized, rusted or whatever and I cannot see any way to remove the lever. This will make taking the engine and ‘box out in one piece impossible. I have to leave the body attached to the chassis for an extended period of time due to lattice frame replacement, so I want to strip everything from the chassis: engine, gearbox, diff, suspension etc., leaving me with a bare chassis with body attached.

It seems dropping the gearbox may be my only/best option. Has anyone done this? Any advice, suggestions, words of warning etc.?

Thanks,

Ian

[2cams70]

That gear lever cap does have some small flats on it at the bottom if I recall correctly. You could either attempt to unscrew it using a very large open ended spanner or adjustable wrench on these flats or failing that use that well known tool of desperation - the plumber's Stillson. The reverse teeth on a Stillson will dig into the metal and grip it.
Also try tapping against one of the flats with a hammer and brass drift in an anticlockwise direction to try and loosen things up a bit. In summary and in order of desperation:

1. Spanner on flats
2. Brass drift on flats
3. Stillson.

If you can get access to the four cover bolts you can also remove this complete with gear lever assembly attached

[StressCraxx]

Ian,

Is there a plastic or metal dome shaped piece surrounding the gear lever? You should be able to twist that off the threads of the top of the gearcase. Looks like this metal one ---

26f6015aas.jpg (40.3 KiB) Viewed 1076 times

You should be able to remove the gearbox from the bottom, supporting it as you move it forward, so the tail drops from the tunnel, then bring it back so it clears the chassis cross brace and set it down.

[661]

Ian,

Is there a plastic or metal dome shaped piece surrounding the gear lever? You should be able to twist that off the threads of the top of the gearcase. Looks like this metal one ---

26f6015aas.jpg

You should be able to remove the gearbox from the bottom, supporting it as you move it forward, so the tail drops from the tunnel, then bring it back so it clears the chassis cross brace and set it down.

The metal one you show has a small grub screw which needs loosening first.

[Ianashdown]

Mine is a steel cover, or at least it was!

Mine appears to be thin sheet metal, and only the very top of the dome is above the fiberglass. Knowing that the part is junk anyway, I tried to knock it around using a large screw driver and mallet. Not a chance! I thought about cutting the lever, but I don’t really want to do that.

I want the engine and ‘box separate anyway, so other than being a back breaking PITA, taking it out the bottom seems OK, I just want to check that it will physically drop through. I though it would, couldn’t see any reason why not, but . . . You never know!

Ian

[rgh0]

To get the box out once the engine is removed you need to drop the nose and pull it forward. The gear lever needs to come of for this to happen I think. I have never tried it with the lever in place but you may be able to drop the front far enough before the tail housing jams in the chassis tunnel ?

If not you can probably drop it far enough to get access to the cover bolts to remove the lever assembly

cheers
Rohan

[Ianashdown]

To get the box out once the engine is removed you need to drop the nose and pull it forward. The gear lever needs to come of for this to happen I think. I have never tried it with the lever in place but you may be able to drop the front far enough before the tail housing jams in the chassis tunnel ?

If not you can probably drop it far enough to get access to the cover bolts to remove the lever assembly

cheers
Rohan

Thank you. Either way it sounds like a cluster ***k! Maybe I will just cut the gearshift lever. It sure would make life easier and presumably they are available . . . hopefully

Watch this space for old age and treachery to win out in the end!

Ian

[2cams70]

If you are going to cut things don’t cut the lever. Cut around the dome using an angle grinder with a cutting disc. The dome is a common old Cortina/Anglia part where as the lever is likely something uniquely Lotus. A large Stillson should work on that though. I’ve never really known them to be particularly difficult.

An oil filter wrench might work on that too - the type with teeth rather than a band

[Ianashdown]

If you are going to cut things don’t cut the lever. Cut around the dome using an angle grinder with a cutting disc. The dome is a common old Cortina/Anglia part where as the lever is likely something uniquely Lotus. A large Stillson should work on that though. I’ve never really known them to be particularly difficult.

An oil filter wrench might work on that too - the type with teeth rather than a band

The problem is the lack of access. It’s almost completely buried beneath the fiberglass.

One thing I will try tomorrow is to put a jack under the ‘box and see if I can expose more of the dome. Then I may have a fighting chance!

Ian

[bitsobrits]

Maybe I will just cut the gearshift lever. It sure would make life easier and presumably they are available . . . hopefully

Ian

DO NOT cut the gear lever. They are made from unobtainium (if you value originality). Once the engine is out, try raising the gearbox to give better access to the domed cap. One of my Elans had a shifter pivot cap that was a real bear to remove, but some penetrating oil and large Channelocks got it done in the end. Buggered up the cap, but those are much more available.

[StressCraxx]

Ian, my apologies, there's no way to remove the gearbox with the gear lever still in place. Do you have any PB blaster rust breaker? Soak it well and leave it for a few hours, then use a small propane torch around the bottom to break the rust. Shield the fiberglass with alu sheet to prevent the FB from catching.

@661, you are correct. The old ones do not have the grub screw that I have seen.

[Ianashdown]

Ian, my apologies, there's no way to remove the gearbox with the gear lever still in place. Do you have any PB blaster rust breaker? Soak it well and leave it for a few hours, then use a small propane torch around the bottom to break the rust. Shield the fiberglass with alu sheet to prevent the FB from catching.

@661, you are correct. The old ones do not have the grub screw that I have seen.

Yes, I’ve been soaking it in penetrating oil for a couple of days. I think if I can jack up the ‘box it’ll lift it so I can get to the thing and get some leverage on it.

I really would like to take the engine and gearbox out together.

Ian

[2cams70]

Don’t try raising the box without loosening the rear gearbox mount of course. Go slowly and watch what is happening so you don’t accidentally punch a hole somewhere.

[h20hamelan]

I use a BoltBuster, electric doohickey thingy from the south of N America

https://boltbusterinc.com/

[Ianashdown]

I use a BoltBuster, electric doohickey thingy from the south of N America

https://boltbusterinc.com/

That’s a pretty ‘cool’ tool!

So many times in the past this could have helped.

Ian