Broken Gearbox.. :(

[m6rk]

It would seem my evora didn't want to leave it's birthplace and promptly shat it's gearbox leaving hethel last weekend

Makes a horrible noise if you attempt 6th gear and 3rd is very graunchy.. sounds rough when you push the clutch in too..  Limped it home in 4th/5th...

Gonna attempt a DIY as i've had the rear clam off before when doing the body repairs but I'm in search of a gearbox.. I dont mind the standard ratios so was wondering if anyone could point me to some replacement donor EA60 boxes?

Found this one but need someone in the know to confirm it'll fit! Will obviously do the clutch whilst it's all out...

https://www.ebay.co.uk/itm/132738991648

[Hangar 111]

It's not a small undertaking, as the engine/gearbox has to come out to separate them.  Also I would seriously consider rebuilding the one you have, rather than putting a scrapper in, as you don't know how long that will last.  At the least, open up the dead one to check what has failed.

Dave

[Chillidoggy]

Ouch!

Having just done the factory tour, whilst in the engine shop we were told that the Evora gearboxes were spilt from the Toyota engines, moved to the other side of the shop, stripped, and rebuilt using Lotus internals. Indeed, we witnessed that happening. But I don't know whether that applies to the earlier Evora cars, though.

[Bravo73]

Are your symptoms similar to these threads?

Although, if you managed to get home in 4th & 5th, I suspect not. 

[m6rk]

yeah I think you are right Dave 'll take it to a gearbox specialist and see what they have to say...

Not very impressed, but thats car ownership i guess, ups and downs...

 

[pete757]

What a bummer...

This is a pretty unusual failure, especially on a lower powered N/A I would have thought?

As well as a new clutch, you could also maybe fit the lightweight flywheel...

Hope you can get it sorted without too much pain mate. 😳

[Cain-it]

Sorry to hear about the failure, hope you get fixed-up soon.

I read somewhere that on the early CR gearboxes, the Lotus components used were not up to or within spec, so these are the ones with possible failure (the was a post on it  on another Lotus forum). I've not heard of failures on the original  LR gearboxes. 

Another post on here, regarding the E4*0 gearboxes, suggested Lotus have done some further internal changes beyond the in-spec CR components / LSD / oil cooler. It seemed to be components to aid shifting quality, in addition to the E4*0 external gearshift  mech. 

Might be worth asking a few deeper questions.... once you open up the failed gearbox, it would be worth getting the latest spec internal components that Lotus use 

 

 

Edited October 5, 2018 by Cain-it

[Cain-it]

http://www.aisin-ai.co.jp/english/news/20150402.html

• February 2005– BG6 — 6-speed
  • Toyota Avensis, Toyota Corolla, Toyota RAV4, Mazda6, Mazda5, Mitsubishi Eclipse, Mitsubishi Grandis, Jeep Compass, Jeep Patriot, Dodge Caliber, Dodge Journey, Lotus Exige, Lotus Evora
  • https://en.wikipedia.org/wiki/List_of_Aisin_transmissions

[C8RKH]

8 hours ago, pete757 said:

What a bummer...

This is a pretty unusual failure, especially on a lower powered N/A I would have thought?

 

Sadly it is well documented (but not too officially I am afraid) that a number of the early NA cars that had the CR gearbox fitted have potential issues. I believe it was to do with the hardness of the metal, essentially it was not hard enough, and so there can be excessive wear and then failure.  I do believe it only potentially affects 2009/2010 cars with the CR box and whilst a small number of failed only, it is still a major repair if it happens to you.

I hope you manage to get it sorted without a ruinously expensive financial hit @m6rk but if it is caused by the "internal issues" it may well be worth seeking a professional view of the failure and then approaching Lotus to see if they would help, though after 8 years that may be a tad of a stretch. I professional and very well experienced outfit like Hangar111 could really help you there.

Best regards and hopes for an acceptable outcome.

[plenty]

Bumping this thread as I managed to lose sixth gear this past weekend - 1-5 are fine, but 6th is gone (engine revs freely with no drive).  2011 S with the Komo-tec EV430 kit.

 

Does anyone have any advice on whether I should replace with OEM Lotus components (on the basis that these have been uprated compared to the early CR 'boxes) - versus the Jubu Performance gear set?

 

@Arregueti

[Arregueti]

@plenty

 

I lost fourth gear, and my car was stock when I lost the gear (and still is) so I am not sure to what extent my experience/cause of default is relevant to you, but I guess it is still "one of the pieces" that gave up... . I am wondering if the EV430 kit played a role in your case.

In my case, I did some reading and considered shortly the Jubu set but, since I live 1 1/2 hours away from them, I opted to have Komo-tec opening the box and change/upgrade the bits required with what I was told were newly developed OEM bits. I have no feedback on the Jubu set, unfortunately.

I was also told at the time and read feedback here suggesting that it is wiser to open the existing box and replace the required bits than to get a new box. At least once you open it you can have a look and replace anything with upgraded pieces, so that you have additional peace of mind on the actual state of your gearbox.

The cost of the replacement bits was negligible (below 200 Euros, if I recall correctly). The substantial hit came from the time spent getting to the gearbox and dismantling the whole thing, as you will have read elsewhere already.

The car has been faultless since the work was done and the gear lever action is much improved now, as I also changed cables, etc. It is also true that I am generally considerate to the gearbox and not using the car on the track.

To prevent further damage I stopped driving the car and had it transported to Mendig. I think that is the general advise, too.

Hope this helps and that you can enjoy the car again soon.

[plenty]

Thanks Jorge - appreciate it.  It's quite possible that the uprated power/torque may have contributed to the demise of my gearbox but hopefully I can future-proof it with an uprated repair.  Until now the car has not cost me anything other than tyres and servicing over 20 months and 10k miles so I'm not too upset especially as it was probably due a clutch soon anyway.  Considering installing an LSD as well while the box is out of the car.

[Bruss]

13 minutes ago, plenty said:

Thanks Jorge - appreciate it.  It's quite possible that the uprated power/torque may have contributed to the demise of my gearbox but hopefully I can future-proof it with an uprated repair.  Until now the car has not cost me anything other than tyres and servicing over 20 months and 10k miles so I'm not too upset especially as it was probably due a clutch soon anyway.  Considering installing an LSD as well while the box is out of the car.

It would be nice to have the gearbox removed locally and either sent to Mendig, or have the komotec parts sent over to you to be fitted by a local gearbox rebuilder.  Let us know how you get on. Good luck.

[Julian73]

On 04/10/2018 at 05:32, Chillidoggy said:

Ouch!

Having just done the factory tour, whilst in the engine shop we were told that the Evora gearboxes were spilt from the Toyota engines, moved to the other side of the shop, stripped, and rebuilt using Lotus internals. Indeed, we witnessed that happening. But I don't know whether that applies to the earlier Evora cars, though.

That makes no sense as Toyota never fitted a manual trans to the 2GR engine.

[Chillidoggy]

13 minutes ago, Julian73 said:

That makes no sense as Toyota never fitted a manual trans to the 2GR engine.

Maybe it was to fit LSD’s? Beyond that I don’t know.

[Julian73]

On 21/11/2018 at 15:24, Chillidoggy said:

Maybe it was to fit LSD’s? Beyond that I don’t know.

  i was speaking of the first part .. of splitting the gearboxes from the engine.  Lotus would receive the 2GR engine and gearbox as separate assembles from  Lotus.  Now the second part is logical ..           Lotus opens boxes to change gear ratios, add LSD and oil cooler pickup tube.

[Chillidoggy]

1 hour ago, Julian73 said:

  i was speaking of the first part .. of splitting the gearboxes from the engine.  Lotus would receive the 2GR engine and gearbox as separate assembles from  Lotus.  Now the second part is logical ..           Lotus opens boxes to change gear ratios, add LSD and oil cooler pickup tube.

Well, I’m glad that little mystery has been cleared up.

[EdCo]

I have an EA60 Lotus Evora standard ratio gearbox for sale. Worked perfectly on removal from car. 37k miles. 

[electro_boy]

As the thread is over 2 years old I’m guessing the OP has sorted his gearbox issue out. 
 

You maybe better off posting on here:   https://www.lotusforsale.com/ad-category/parts/evora-parts-for-sale/
 

 

[au-yt]

It this hasn’t been mentioned, the box starts life from a Diesel RAV 4. Unusual design as it’s a triple shaft box with two crown wheel inputs, and by the specs has two diff ratios, ( hence the low load chatter)

1, 2,3,4 diff is 3.78:1 & 5,6, reverse are 3.24:1 on the 4xx series.

I believe the early NA cars are taller?

[EGTE]

I read somewhere the early NA cars had Avensis diesel ratios or something. Top would be good for something crazy like 240mph at the NA redline 😆