Lotus Elan

Lotus 5 speed gearbox

PostPost by: bcmc33 » Sat Jan 02, 2010 8:48 pm

AussieJohn wrote:Hi Brian C. The propshaft which was modded for a "baby" measures 29.125" flange to flange with the sliding spline fully comressed; the spline travel is 43 mm.

John,

My current thinking is 29.25", but I'm a little concerned about your spline engagement figure.

By my assessment the 4 speed slip yoke spline engagement as installed is 76mm (3") and fully engaged is 96mm (3.78"). I would expect the 5 speed to be in the same ball park.

I will call Sunday.
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PostPost by: AussieJohn » Sat Jan 02, 2010 9:49 pm

Stuart, it would be great if you get a chance to measure your propshaft; also the amount of shaft exposed at the spline, cheers, John.
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PostPost by: bcmc33 » Sun Jan 03, 2010 10:32 am

John, my friend,

I woke up this morning thinking of nothing else but putting a hole in the chassis - what a pathetic life some of us lead.

Regarding a hole in the boot - this is the best I could do to eliminate the frustration of filling the diff:
Diff Access Plate.JPG and

Diff Access Hole.JPG and
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PostPost by: AussieJohn » Sun Jan 03, 2010 11:48 am

Great idea Brian, never thought of that! I have been covered in diff oil in the past; not very pleasant, cheers, John.
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PostPost by: john.p.clegg » Sun Jan 03, 2010 12:19 pm

...or this which gives access to the handbrake tree also...

John :wink:
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boot diff access.JPG and
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PostPost by: bcmc33 » Sun Jan 03, 2010 12:36 pm

john.p.clegg wrote:...or this which gives access to the handbrake tree also...

That works fine for the +2, John, but not for a Sprint. :(
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PostPost by: AussieJohn » Sun Jan 03, 2010 12:56 pm

Brian, 2" of male spline welded to propshaft into a much longer female spine being part of the yoke, PS good to chat, John.
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PostPost by: john.p.clegg » Sun Jan 03, 2010 3:50 pm

Brian (friend)

Not 100% but think Aussie john has a plus2?

John :wink:
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PostPost by: elansprint » Sun Jan 03, 2010 4:57 pm

I think John is referring to the sliding spline fitted in the +2 shaft which has a flange each end & brian is referring to the sliding yoke on the std. elan as props are different
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PostPost by: bcmc33 » Sun Jan 03, 2010 5:22 pm

john.p.clegg wrote:Not 100% but think Aussie john has a plus2?

I spoke to Aussie John today and he has a +2 propshaft that has been shortened to fit an Elan.

elansprint wrote:I think John is referring to the sliding spline fitted in the +2 shaft which has a flange each end & brian is referring to the sliding yoke on the std. elan as props are different


The slip yoke on the +2 is the part that fits to the gearbox end, and the male spline is on the end of the tube that fits to the diff end.

My only concern from Aussie John is the length of spline engagement - I would expect about 75mm.

I shall go to see one of the local propshaft makers this week to discuss this issue.
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PostPost by: stuartgb100 » Mon Jan 04, 2010 6:44 am

AussieJohn,

Best I can tell is that the distance between the gearbox and diff flanges is 30 inches.
The length of the sliding spline that is visible is 1 inch.

Note that this is a purpose-made propshaft, not a modified +0 or +2 variant.

HTH.

Regards,
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PostPost by: AussieJohn » Mon Jan 04, 2010 9:18 am

Thanks Stuart, it seems we are all around a similar setup, cheers, John.
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PostPost by: mac5777 » Mon Jan 04, 2010 11:17 am

Hi Brian, its a little off subject but regarding a hole in the boot, your pictures helped greatly. I have been wanting to cut a hole but was not sure where actually without too many missed cuts. I have the same size rubber plug but have been told that it makes too big of a hole. I also have 2" plug. My question is the diff filler nut in the center of your plug location? And would 2" be too small to access the Diff filler plug?

Thanks again, Sarto
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lotus elan 1966 S3 FHC
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PostPost by: bcmc33 » Mon Jan 04, 2010 12:07 pm

Hi Sarto,

I did this mod when the diff was out, and thought what a stupid place to put the filler hole. The diff was put back complete with oil, but what about the future?
The item I used is a boat access cover about 5" diameter. I have to confess that it was not an original idea - I got it from this forum.
I also had a number of large rubber plugs, but thought an access cover was a better and more professional method.
These additional pictures may be more descriptive than my first picture:
Diff Access 4a.JPG and

Diff Access 5a.JPG and
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PostPost by: mac5777 » Mon Jan 04, 2010 7:55 pm

Thanks Brian, I like that you used a boat flange to keep the structure in place after cutting out the fiberglass. Real professional!! Now that you mentioned it, I think it was Phil who installed one.
After you installed the diff. where in the 5 inch hole was the drain plug positioned? In the middle or is it offsite in any direction? Your finished opening looks like about 4". I can get a good idea from your photos where to cut. I'm still thinking that a 3 5/8 inch hole and the rubber plug I pictured, would be more my speed, (simple) The hole would have to be positioned just right to fit a wrench and a filling tube.
It is about time to check and/or change the oil. Funny that there is no drain plug to change and get out any metal pits etc. They must pump it out if they have to.

Thanks again, Sarto
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