Lotus Elan and Lotus Elan Plus 2 Forums

(Note: I have also on posted this on Facebook Classic Lotus Elan and Plus 2 Owners)

Finally got around to posting this hopefully useful tip for freeing seized Lotus Elan Girling brake or clutch master cylinder metal type caps. Last year I discovered both of my metal caps extremely seized. I tried all sorts of methods, even purchasing a purpose-made removal tool. All to no avail. The caps were well and truly stuck. I eventually got to the point of googling for a source of new brake and clutch master cylinder replacements when I suddenly had an eleventh-hour idea. Using 2 large jubilee clips (size 4 & size 3x) (I would recommend actual jubilee originals as the thread goes all the way around the clip) and a toothed fan belt (e.g Mk3 escort Motorcraft EJD77R). Cut the toothed fan belt (260mm for Brake) & (200mm for Clutch) and insert the sections into the jubilee clips. Place the jubilee clip loaded with the fan belt section around the cap and tighten as tight as possible (I recommend using a small socket and wrench as opposed to a screwdriver). Then tap the jubilee screw head using a brass bar and hammer in the anti-clockwise direction. Worked perfectly, on both caps. (see photo).

As a preventative, I have applied a bit of brake rubber lube (like that that frequently comes with m/c rebuild kits) to the reservoir threads prior to installing the cap. So far it has worked well.

Red rubber grease. If it doesn't offend you too much you can get the plastic tops cheaper and easier.

Thanks derek uk & crannyr. The caps cleaned up well on the inside. I did in fact use the Red Rubber Grease on the cap seals. When I remember I check that the caps are free to move each month.

I;m looking for metal caps for brake and clutch. It's on my sand rail. I did see some picture on your site how can I get some? Thank you

Have you tried Sue Miller, Paul Matty, Kelvedon.

USA? Try Moss the MG people. I'd go for the plastic ones for your sand rail. As you've seen, the alloy ones can be a pain!

I always tighten very little and use a rubber glove to unscrew. Or if difficult Oil filter removal tool.
Alan