Lotus 5 speed shifter

[mbell]

It maybe the plastic ball that is crumpling on mine had completely gone on yours. That would allow the sick to raise up and may separate from the selector mechanism on the box.

Basically you need to pull the trim and check if it's screwed diem as John said. If so pull it and check the stick out.

If possible you should try and get 3rd or 4th gear before removing the stick.

[rgh0]

Yes probably the plastic support that screws into the gear box for the gear change lever ball has either fractured or unscrewed.

Happened on mine in the mid 90's ---- luckily only about 100 metres from home

cheers
Rohan

[vincereynard]

Here are all the bits I got with an Elite S1 lever from lotusbits.

Anyone know where I can source a cone spring to replace the rubber bellows? Then it would be easier to adjust the tension.

Vince

[rgh0]

I adjust the tension by shimming the rubber bellows under the circlip on the lever that retains it at the top.

cheers
Rohan

[mbell]

When I strip my stick to replace the lower ball (left part in your pic) that is falling apart, I am thinking about removing the rubber bellow and replacement them with a spring. Then threading the shaft so that I can use a nut to adjust the pre-load on the mechanism to allow me to tune it. I was thinking a normal compression spring with larger diameter washer at the bottom would be fine. This would just be to spread load on 4th part from right in your picture and stop the spring chewing it up.

At the minute I've just done what Rohan and suggested and stuffed a grommet between the bellow and clip to increase the tension. Think it might be a bit much but won't find out until I refit the box (and engine) in the car and get to drive it.

[vincereynard]

Of the three "bellows" I have, 2 are split. The best is maybe 40 years old+.

Hence the idea of a spring replacement. I can see a problem in threading the shaft ,as how you would be able
to get the die and nut past the kink? My idea was a simple collar, (or even a large nut), drilled and threaded to take a grub screw. OR a washer and a strong hose clip?

After than some sort of 3rd / 4th gate to ease the 2nd > 3rd change.

Vince

[mbell]

I can see a problem in threading the shaft ,as how you would be able
to get the die and nut past the kink?

You have a good point, I haven't looked at this in a lot of detail of how I'd actually do it or try to do it. So interested to find out how you get on.

After than some sort of 3rd / 4th gate to ease the 2nd > 3rd change.

With the (strong) spring for 5th/reserve I wouldn't have though you needed anything here. I don't think I had any issue getting third from second. I recommend trying it with a decent gear stick before worrying about it. I don't think there is much you can do without removing the engine and gearbox anyway.

[vincereynard]

You have a good point, I haven't looked at this in a lot of detail of how I'd actually do it or try to do it. So interested to find out how you get on.

Edit 170217
A better video with a new camera -

https://youtu.be/xSyhX_8Lv9I

It jumps about a bit as I'm playing with camera angles and lighting.

[gjz30075]

Good videos, Vince. Thank you.

[mbell]

Yes, very helpful video and interesting to see how you tackled this. Looks like a good solution. Thanks for posting the video's.

In the video it was the first timed a got a good look at the troublesome ball. I'd assumed that it roughly matched the diameter of the blue cup (~1 1/4" from memory) but that doesn't seem to be the case and might mean the ball I've bought might work as a replacement. If you happen to still have it out of the car could you post measurements of the ball? (Don't worry if it is in the car.)

Thanks,

Mark

[vincereynard]

Mark,

As it happens I'm planning to fit the new lever tomorrow so I'll measure it before hand.

I have a neighbour your runs an engineering firm he mentioned he could have some made it it came to it.

Vince

[mbell]

Thanks Vince appreciate it.

I have bought a 1" (from memory) plastic ball that I was hoping I could drill a hole though and cut the bottom off and use. I'd given up on that idea as thought the ball was too small, but watching the video has made me wonder if it might work or not.

[vincereynard]

There you go.

[mbell]

There you go.

Thanks You! Really appreciate it. Now I must dig out my new ball and see if it was 1" or 1 1/4" as from your measurement looks to be 1 5/16" in old money, so 1 1/4" ball might just do it. If not local machine shop might be able to make me one up.

[vincereynard]

Mark,

I've just been told by the chap I borrowed the gearlever of that his brother has found a source for replacement balls. A soon as he gives me the address I'll let you know!

Vince