Popping out of gear

[264889socal]

The purported rebuilt transmission in my Elan has a habit of popping out of 4th gear when driving on a level stretch of road with a neutral or light throttle. The workshop manual talks of insufficient pressure on the detent springs and a problem with the main shaft of the transmission. One thing I noticed yesterday, was additional movement of the gear shift lever to the rear when the vehicle in in 4th gear. This movement is not present in any of the other gears. Any suggestions on what to look for or other ideas would be appreciated before I remove the engine and transmission.

Also, could anyone supply the correct hole diameter in the plastic console cover over the transmission tunnel.

Any help appreciated.

Rob Walker

[garyeanderson]

Hi Rob
Maybe someone forgot the overrun stop tube that goes over the 3/4 shift rail when it was rebuilt. Not sure it would cause those symtoms.

Gary

[gordonlund]

Hi Rob,

Sounds like your 3 - 4 gear selector fork is worn and not pushing the dog into full engagement. It was a common fault with Ford Cortinas in the 60's. 3 - 4 selector is the most common used and thus more liable to wear before the 1 - 2 selector fork.

New selector forks are easy to get, but I would imagine that with that kind of wear the rest of the box must be ready for reconditioning.

The box can be rebuilt cheaply in the UK. I don't know about the States, I presume you are in the States.

Regards

Gordon Lund

[sk178ta]

It could just be the lever fouling on the console, not going fully into gear.
Try driving consoleless as it`s the simplest thing to rule out.
Jim

[264889socal]

Thanks for all the replys.

When I bought the car last year, the DPO said he had purchased a complete rebuilt gearbox. Being an S2, I presumed it had the close ratio gears, however upon after getting the car in running condition, it obviously had the semi close box. I well remember the long first gear in my S7 and was wishing it was equipped with the same ratios.

With the console removed and nothing to interfear with the shif mechanism, with the gear lever in the 4th gear slot, I can get further movement of the lever when pressure is applied. Does not do this in 3rd or in the 1-2 location.

I know I will have to remove the combined unit to even check the spring height of the detent springs. So going further may be the only recourse. I presume one of the local vendors located on either coast will most likely have the needed parts if required. If I am off base, some advice may be necessary. If it starts getting too involved, it may be time for investing further dollars into a 5-speed unit. I believe somewhere I read the unit out of a Merkur was a bolt up with minor modifications. or purchase of the needed parts to adapt. The other choice would be on of the units available from England. However the sub frame is still the original Lotus unit, which may complicate things.

Rob

[memini55]

Hi Rob
Just completed a rebuild on my sons semi close box for his +2. His was popping out of third and on ocation fourth. We pulled motor and box for rebuild and I found it somewhat easy with the top cover off to select gears and watch the internals work. If you take care and leave the indent balls in place to see normal section position you will be able to see how the syncro hub and gears mesh. I found with ours that third did not fully engage but with preasure held on shifter it would stay in gear.
The sugestion from Gary about the tube not installed would only effect third as it is in that direction of movement which it limits. The shifting fork is easy to watch and could be a suspect. When you look in and watch it shift the hub should cover the brass ring and completely cover the cog teeth on the fourth gear. This is common on all gears.
Our problem was too much clearence between third and fourth requiring more motion of the hub than was possible. Now the cause was fun too find and was a multi failure. The spacer oil slinger between the rear shaft bearing and first gear was broken into pieces thus allowing everything on the rear shaft to move arround. Then first gear and the first and second syncro hub groung off there mating surface cause additional movement in the complete rear shaft gears and syncro hub. That in turn caused the clearance issue between the front and rear gear sets.
Don't know if this will help but it was a fun project and is now behind us and now completing the motor.
Good Luck
Mark

[264889socal]

Mark,

Thanks for that information. Not planning on pulling the unit for a couple of weeks. Other projects on the front burner. All of the replys have been a great help. I am sure when I get it layed out on the bench I will have more questions.

Rob

[oldokie]

If you wind up needing a local vendor you might try Anaheim Gear. I've never needed them for a Lotus project but they've bailed me out on several other gearboxes. A lot of the shops in this end of California send them work, jack up the price, and act like they did the job inhouse!