Proper clutch disc for a Lotus 5 speed?

[gjz30075]

Before I have the hub machined down 5mm, per the Lotus Bulletin, please take a look at the pics. It's
a 8 1/2" disc that I got some time ago and I've always wondered about the small amount of friction area.
The 5 speed disc (alleged) is sitting on the Lotus Bulletin in the pics.

I measured another 8 1/2" disc I have (not from my car) and the friction material on it considerable larger.

So, is this a proper disc for a 5 speed? Splines fit fine, btw.

[john.p.clegg]

Greg
I wouldn't worry about 1/32" less friction material .

John

[gjz30075]

John, more like a 1/4" (diifferent rulers giving illusions). New pics using the same ruler and the 5 speed
disc on top of the other disc

[john.p.clegg]

Greg
I'd check the OD's , are they both 8 1/2" ?

John

[rgh0]

The NOS plate has 6 torque springs, most new plates only have 4. I have seen a number of the 4 spring plates fail with the spring coming loose and falling out if you do lots of hard, drop the clutch, starts . Never seen it happen with the older style 6 spring plates. Assuming it is 8.5 inch O/D and the spline fits I would happily use it even if the width of the friction face is a little less than your old plate. Just check the dimensions of the spline hub length versus the Lotus service bulletin and machine as needed to avoid the plate binding.

cheers
Rohan

[gjz30075]

Yes, both are 8.5". Rohan, I do plan on having the hub machined down, per the Lotus Bulletin. The disc
is sitting on the Lotus bulletin now; just had to confirm I had the right disc.

Thanks guys!

[gjz30075]

Ok, just a slight hijack here, if you don't mind. What clutch alignment tool is used for this application?
Any 'off the shelf, with a part numberer' type of tool available?

[john.p.clegg]

Just nip down to your local motor store and ask for one....or if you want all the whistles and bells...

http://www.ebay.co.uk/itm/Clutch-Alignm ... xyiBpSLF11

or if you have access to a lathe it's a five minute job...

John

[gjz30075]

Actually, I just remembered I have access to a broken Elite 5 speed box. I'll try to get the input shaft from
it. Should do the trick
Thanks!

[gjz30075]

Well, not as easy as I thought. Any tricks to getting the input shaft out of the 'box? I've removed the
front cover and the most the shaft moves out is about 1/2", then a hard 'metallic' stop. I just can't see
why it doesn't just come out. Connected somehow internally?

From what I can see from this pic and the exploded view, the lh side of the shaft is a female to receive the
4th gear shaft which is male, both keyed.

[mbell]

How and how hard are you trying to get it out?

I think you have to remove it with bearings and 1st motion shaft from the case. The manual says to pull/ push the lay shaft out first, but I've never could figure out why from looking at the box.

Interested to know how you get on as likely have to do this job at some point in the future...

I aligned my clutch issuing the gear box with bell housing removed and hooked to engine host with engine on stand.

[john.p.clegg]

The layshaft has a gear on it , which interferes with a gear on the input shaft stopping it coming forward.

http://www.lotuselan.net/wiki/FE_-_Gear ... rnals_%2B2

John

[gjz30075]

Ok, I thought #1 would slide off #6. Does #7 tie them together, hence the gear interference??

Mark, I simply pulled off the front and top covers and started pulling.

[john.p.clegg]

.. and it's locktite'd into place , you don't want that coming off.

John

[gjz30075]

Thanks John, I guess more disassembly is required