Plus 2 diff removal

[Andiken]

Hi all, how do I get the diff out of the chassis? The back end is completely stripped off the chassis, the two top bolts are out and the diff is like a loose tooth but won't come out!

Do I need to remove the top diff mount rubber bushes that pass through the chassis? If so how do they come out please?

Frustrated of Lingfield!

[alan.barker]

Your car has a stiffening brace on the diff which you must remove first while it is still in the chassis.
There is a bolt that goes through the brace and into the diff. From memory the size is 1/2""AF.
Not easy to get at, just try and stay zen.
Alan

[Andiken]

Aha! Thanks Alan, seen it. Will removing it give me enough wiggle room to get it out?

I'm guessing so.

Thanks again for the speedy reply!

[alan.barker]

Yes,
it will give you room but check to see if the chassis has not been bent upwards under the diff because of bad use of a jack in the past. You may need to adjust it but it is still a very tight fit. You will need to try many different positions (said the actress to the bishop ).
It will only come out on the left side/nearside UK.
Alan

[JonB]

Hey Alan, is that the same for the Spyder chassis?

[Andiken]

The results are in! After a tense struggle and assuming many different positions, including the Lotus position I'm pleased to announce the final score is Andy: 1, Plus 2 diff: Nil!

It was VERY tight indeed, fractions of a mm clearance!

Thanks again for the help Alan.

[stugilmour]

Hey Alan, is that the same for the Spyder chassis?

Was for my Spyder chassis. Then again, tight enough on the left I never tried the other side with much enthusiasm.

Stu

[JonB]

Well done Andiken!

[MarkDa]

Patience is a virtue!
In the limit we must remember that if someone got it in we can get it out.
A lot easier without the body on of course!

[Peter +2]

Possibly not too late.

Before you put it back, type in ?Lotus Elan Differentil Removal? into YouTube and watch Col Croucher?s how to video.

He suggests some simple modifications to help the process. Not done them myself but will consider the next time the diff is out.

Peter

[Andiken]

Thanks for the heads up Peter, I?ll have a look now.

[Foxie]

Your car has a stiffening brace on the diff which you must remove first while it is still in the chassis.
Alan

No need to remove the diff upper mounts.

My diff has the brace but it goes out and in with the brace in place.

I disconnect the lower wishbone from the upright and swing it vertically downwards into the pit. You might need to remove it altogether if the car is just jacked over the floor. The diff sort of rotates out and down on the lhs, lots of jiggling required !

[Hawksfield]

Hi Andiken

While you have the diff out grind of the raised section on the diff nose as shown in my image
You can grind of this area if you take your time and don't get it too hot.

In addition see the removal procedure.

diff procedure from manual.pdf

(1.12 MiB) Downloaded 357 times

[alan.barker]

Sorry ,
but to be honest for me i wouldn't do that but that's just my personal view. It's not very often you remove the diff and if it came out it will go back.
Alan

[Peter +2]

Hi Alan,

I am led to believe that the "nogging" for want of a word is sacrificial as only used in the manufacturing process for machining.

I am happy to be corrected.

Peter