Esprit Turbo project car - part3 - the further continuation

[Lotusfab]

So split pin is in, using same tool I made. For the bearing install I'm going with 2 hrs of freezing on the bearing at -17 degrees and 20 minutes in the oven at 110 degree, unless the wife catches me and I have to remove it and run out the back door in a hurry!

[Andyww]

When I did mine I had to ask the wife how to turn on the oven as I have never used an oven before!

[Fridge]

What's an oven?

[Lotusfab]

Well I'm not an expert on this and anything on here you see it copy is entirely at your own risk. This is just a record of what I did for fun!

Bearing rear

in the end the bearing was at -17 degrees for about three hours. The first fit the hub carrier was in the oven for 20 mins at  100 degrees. I had to press the bearing in. The second was in the oven for 40 mins. The bearing dropped straight in with no press! I know how I will do it next time!. It's still not finished and to be honest a pain of a job. My advice let the experts fit the bearing and do the rest yourself! Oh, I used Loctite adhesive on the outer surface as per the Lotus manual.

The studs don't fit in the split pin so the split pin with need a bit of fettling! The clearance in the hole needs to be about 1/2 inch imperial.

[Lotusfab]

I intend to report as to how this Aqua blasting hold its appearance over time. There is nothing in the web, as far as I can see. The only finish to be applied here is ACF50.

[red vtec]

Hi I need to do mine, I did the same process when I fitted the translator bearing.

Is there any risk of cracking the casing if the parts were tight when it cools down?

Chris

[Lotusfab]

Hi Chris, all I can say is they have cooled down with no issues. There's always a risk but no other way. The safest course of action is to get the professionals to put the bearings in. They do it all the time so very low risk. But I did it also with no issues.

[Lotusfab]

One side done!

I coated the hub carriers in ACF50, lets see how it performs!

I've bought two lower link to chasis bolts in the last three years. It's the wrong size in the parts manual it's 80 mm long!😡😡😡I keep forgetting and ordering the parts manual size! Now at last I'm rderingbthe correct size!

[snowrx]

I see Q has been working on those upper links since FYEO...

[Lotusfab]

 

Yep Q in the form of Lotusbits. An adjustable upper link on both sides! 

I've done this job a few time now.

The easiest reassembly method.

Put the lower stud in first through everything and the nuts loosly on.

Then use a pry bar on the spring and slot the bolt through the upper link and hub carrier.

then jack up the hub carrier until the trailing arm bolts align and slide the bolts through. 

Job done! 

[drdoom]

7 hours ago, red vtec said:

Hi I need to do mine, I did the same process when I fitted the translator bearing.

Is there any risk of cracking the casing if the parts were tight when it cools down?

Chris

Chris,

I've done this job on both my Esprit and my classic Elan, nothing to worry about unless brutality is involved. As Fabian demonstrated, adequately heating the casting permits the bearing to drop into place and, yes, the bearings should be cooled if only for retention of grease against heat soak from the casting. The parts are designed to fit tightly once assembled, the interference dimension resulting in a moderate clamping force that does not unduly stress the casting.

Cheers

[Lotusfab]

Update

suspension rebuilt and back on wheels! Now the fun part.....Ohhhhhh s...t!WTF!!!,....

I knew I should have paid the professionals! 

Anyhow as Im already here I might as well rebuild it.....

Just pics......

New gear to replace the chipped one, wax on wax off just like the Karate kid!

And then put it on the shaft. Sorry, no trade  secrets, It's a kind of Magic! 

And then replace the pinion bearing, but first a read of the manual and some tea! I of course cleaned everything! It might be a very long cup of tea whilst Inthink about this! 

[Lotusfab]

New bearing on!

[Lotusfab]

Well I'm disappointed nobody pointed out the gears were incorrect on that shaft! Just testing! Here's the correct version...

[Lotusfab]

Well there is a kind of magic going on here, but not in a positive way! Somehow the gears reordered themselves! Still no harm done I realised and was easily able to reorder them correctly using the manual and my pictures. I have the pinion shaft and reverse gear back in. I may have to dismantle it again to get the rest in, but so far so good. If I did this again it would be much easier. But I have to say if I lived near the Wirral I would have taken it to Alan Voigts. If I live near Harry I would have taken it to him. It would have been much quicker! Putting it back together will not be difficult but the real test will be how it performs and how many years it lasts. I've got a feeling longevity will not be a problem at my age! In a weird way it's nice to do something different, I always like a challenge especially when I'm told I can't do it! 

So far,  new bearing in. May have to partially remove it again -  we'll see.

[Fridge]

TBH gearboxes are specialist things and unless you're keen to learn, or short of funds, they're best left alone IMO.

Voigts were helpful when I had my S1 gearbox/transaxel done. Though I had mine done by a transmission specialist near me. With me supplying parts, including the "Citroen" tool, which they machined down to fit.

Having road tested it last week it seems to work thankfully! It was rebuilt in 2017.

[Lotusfab]

I don't disagree. I've been messing around with this for a few weeks now. I am able to spend as much time  on it as required to get a good result. I already understand it pretty well. However,  go and get a specialist they'll do a great job and it will work! I've started so I'm  going to rebuild it to the highest standard I can.

[Paul Coleman]

The only thing I did in relation to my gearbox was replace the circlip which had rusted out. Other than that I changed the oil and it's been fine ever since. If it ain't broke, don't fix it!

[Lotusfab]

Well, you know me Paul - it all has to come apart! 

To be fair, it's a pretty simple gearbox. 

I'm now just about to remove the shafts again, drop the piñon gears down and install the primary shaft. Just wanted to see how it all fits. Ohh and of course I will measure the pinion height, as I have replaced the pinion bearing.

[Lotusfab]

I am quite enjoying this  challenge. It's make me work harder and concentrate more when I'm told I can't do something or should leave it. When it's running perfectly it all seems so much more worthwhile. Keep it coming! I have to recommend a professional does this, however....

👍🏻👍🏻👍🏻👍🏻👍🏻

If this isn't working perfectly after the rebuild the solution is simple, take it out and do it all again! 

Now where did that ball bearing go! 😀😀😀😀

[PhilW]

You're a brave man Fabian!

[Lotusfab]

Brace or foolish, the two are quite closely linked!  Anyhow .....they are back in! New bearings and third gear with synchro. Now just have to wait for some parts - two weeks forvtge seals! 

Now the rest of it! 

[Andyww]

I really like the design of that Citroen box. Its much neater than other transaxles such as the Renault or Hewland etc. Makes you wonder why they are not all designed that way.

Probably stronger than the clam shell design of the others as well.

 

[Lotusfab]

Pinion height measured using a vernier and straight edge. Consistent with the engraved figure. No reaso it should have changed. Speedo gear back on. Loctite used. Now the rear casing, can't find in the manual any use of sealant or gasket. It was sealed with silicon when I took it apart. More research job halted.

 

Disregard, found the reference to sealing all mating faces!

[Andyww]

This is the best stuff to use