Lotus Elan and Lotus Elan Plus 2 Forums

morning,
Just got the bearing sandwich off," all's well in the world" thanks for all the help again, again and again.
Gerald.

Gerald,

I was going to refer you to the diagram - but as you have discovered it all makes sense when you have it to pieces.

There are sevaral tips on here regarding the rebuild. Particularly roughing the polished surface on the cone on the gear so that the synchro bites, and using sealant on the bolts.

I use the water pipe to keep the various washers in place while inserting the layshaft - can be a bit of a fiddle. Also take note of the orientation of the synchro springs, and be carful not to slide the 3/4 outer until you have the front bearing and tailshaft housings bolted on - you will be tempted to check the engagement, the bearing carrier will drop out and the springs/bars will slip - you have to drop the layshaft to take the gears out and put the spring back!

Clean all of the bolt holes otherwise the dried crap in them falls into your nice new gearbox.

Very rewarding when you finsh!

Good luck