Lotus Elan and Lotus Elan Plus 2 Forums

Hi,

I?m trying to install the engine and gearbox in my S4, but I can?t insert the propshaft into the gearbox. The Extension Housing seal is new, already try with the engine and gearbox combo, gearbox only... removed the right seat to acess the tunel... any help?


thanks

Whilst awkward, with someone turning the front pulley (on combo) or gearbox (gbox only) input shaft, it is possible with your hand through the hole (positioning the yoke) to allow engagement. The secret is the turn bit to engage on the splines otherwise you can maul your privates off and get fibre glass rash on your wrist.

PS don't forget your grease on the seal/yoke shaft.

Mike

already turn the splines but it doesn?t engage....

Hi,
Probably best to remove propshaft and check if it fits easily into housing when removed. If ok, keep trying. If not, it may be the wrong seal. Only four bolts to undo!
Alan P

Legal small print .....always assuming that it's the correct size seal, the original gearbox output splines and the correct propshaft ...

Firstly, make sure that the splines in the propshaft are clean and without burrs. Maybe prod / clean the splines on end of the gearbox tail housing also.
Then I found that lots of oil around the inner lip of the seal, plenty on both the inside (splines) and outside of the propshaft yoke, then while lying underneath, tapping the other end with a rubber mallet while gently rotating the propshaft encouraged it to start it's way in passed a new seal and onto the splines.

With the body off, this is a one person task. May need two people with the body obscuring access.
Peter

Can we assume this was a complete car at one time and this propshaft, trans, etc, came from this car?

engine and gearbox were removed by me for rebuild... all major parts are the same except bearings and seals! I will give it a try today, if then don?t engage then I will have t dismount the propshaft!

I found it easier to undo the propshaft / pinion coupling and insert the splines with the engine and gearbox in place. Is that what you have?

Hi,
You need to take prop off and try in off the car.

I brought a new alloy housing obviously complete with new bearing and I couldn't get mine to fit - ended up replacing bearing.

Just my opinion but you should trial fit everything off the car.

Regards
Steve

If a new tail shaft bearing has been fitted I suspect it may be that. They maybe supplied undersize and require reaming to fit the tail shaft in

cheers
Rohan

I had the same problem last year when for the third time reinstalling the engine/gearbox (gearbox leak) I couldn't get the splines to mate. I eventually got a file & made sure that the prop shaft splines had no burrs on them, fitted together fine after that. I don't think it takes much of a burr to stop them from engaging.

I have done it finalyy! thank you all!