Broken Gear Linkage/Cable

[Vaughnc]

Not sure the best way to ask a question on the forum - not needed to do so before now - so hopefully this is OK.

Yesterday I lost all gears just 300m from my destination. Got recovered back home (low loader). Funny thing is last time I drove a fibreglass car (TVR) to my parents it too had to be returned on a low loader!
Anyway, it is evident that the linkage has snapped/broken/failed. I can change gear with the selector, gearlever is floppy as hell. Looked for a sign of what has failed - in engine bay at gearbox end and at gearlever end (removing gaiters and securing bolts). I cannot see what's broken. I can see two cables connected to the gearlever and also at the gearbox end so they've not disconnected at either end as far as I can see. There is no resistance to front-to-back movement at all so I can only guess that one cable has snapped mid-way or at least somewhere that I cannot see.

Reading through the forum and wiki it seems likely that I need to replace the cable. Trouble is I have just one week to do it. I'm supposed to be on a Classic rally week after next in France, so I really need to get this done pronto! It does not look like something I can do myself - I cant seem to access to the area behind the gearbox, and I can't safely raise the car to get underneath (do I need to?).

Does anyone know (A) a good place where I could get the correct cables and (B) who could do this for me ASAP (i.e. a garage)?

I've emailed Steve Williams in Maidenhead (where I live) hoping he can reply quickly and help. But in my experience he is either booked up or away racing so I urgently need an alternative in case he is not available.

My Elan is an S2 number 750.

Thanks in advance. Here's hoping someone sees this post in good time
Vaughn

[Steve A]

I think Trevor B is in your area and he uses a garage he highly recommends

[Vaughnc]

Thanks Steve. I believe Trevor is in Gravesend - near Maidstone but not Maidenhead - other side of London. I guess Maidstone Sports cars would be best bet that side of London.
I can drive the car a short distance but that far would be a chore in 2nd gear!

[Saltire]

Hi Vaughan

Re the cables: the generally accepted solution is to fit a set of these, supplied by Brit-Car-Nut of this forum. I’m sure he’ll be along in a minute . . .

Re garages: you might try Lakeside Engineering if you feel you can get that far. No personal experience, but I know several who’ve used them and given good reports. I have a good chap, but he’s in Wiltshire, and that’s probably a bit far from Maidenhead in second gear

Good luck!

[muley]

Hi Vaughan


Sorry to hear about your plight.

SJ Sports are listing a cable and bracket set. Not sure if their set is (a) available or (b) compatible with the S2.

If it's not compatible then you'd need to replace both cables and the bracket.

The job is pretty straightforward. Simply put ~ disconnect the cables at the gearbox end, unbolt the gearshift assembly and wriggle the cables back into the car. No need to access from underneath.

Replacement is the reversal.of that but you have to wriggle the cables through. I found it useful to tie a bit of string on the old cables before removing them.

I'll try to extract the appropriate bit out of the manual for you.

If you want a hand just ask; I don't live far away..

Rgds

Jim

[muley]

p.s. 3rd is a better general purpose gear - you can go far in that gear..

Jim

[Brit-Car-Nut]

This is a new situation for me. The S2 has completely different shift cables than the earlier SE and NA.

The SE and NA cables had plastic bulkhead mounts that over the years dried up and would break where the snap rings went to held them in place.

I think ALL S2s have metal bulkhead mounts with nuts on either side of the abutment bracket for adjustment.

I have never seen a set of S2 cables, just A-B cables, Bob B's cables and those I make.

It is possible the fore-aft cable has the same plastic "ball socket" at the shift lever end as the SE and they are known to break.

You could disconnect the cables at the gearbox end and push and pull on them to see if the shift lever is moving. If one moves the lever but not the other, attach a string to each and then carefully
remove the shift lever assembly enough to look at the cables where they are attached while someone moves the cables at the gearbox again.

It the "ball socket" is broken, there is enough shaft to cut off the broken part and after threading the shaft, install a spherical rod end.

If you need any pictures of that repair, I can email them to you later tomorrow as I have an SE cable with the plastic "ball socket" and another SE cable I repaired by adapting a Rod End to the shaft.

The S2 Fore-Aft cable is still available from a Lotus Dealer, SJs, SW Lotus and similar. Part # B100F0030F and the Lotus price is £144.50 + VAT.

[Steve A]

Thanks Steve. I believe Trevor is in Gravesend - near Maidstone but not Maidenhead - other side of London. I guess Maidstone Sports cars would be best bet that side of London.
I can drive the car a short distance but that far would be a chore in 2nd gear!

Doh
I'll get me coat

[Dave Eds]

Thanks Steve. I believe Trevor is in Gravesend - near Maidstone but not Maidenhead - other side of London. I guess Maidstone Sports cars would be best bet that side of London.
I can drive the car a short distance but that far would be a chore in 2nd gear!

Doh
I'll get me coat

And my map........

[Vaughnc]

BCN, Jim
Thanks for your helpful replies. I have been reading as much as I can about the problem this evening - the Service Manual, Forum posts, WikiLEC etc. It looks quote "do-able", I just need to see if I can actually access the space behind the gearbox. Obviously others have done this before so it must be possible. I am going to look again shortly.
Jim - I might take you up on your offer of help:) You can find out what I've done to the car since April - I'm very happy with how it is now (despite this setback).
All the best and thanks again.

[Vaughnc]

Thanks Jonathan for your reply. I have heard of Lakeside Engineering. Looks like they are nearer than I thought, and not very far from the garage I use for my SAABs (who apparently have an ex-Lotus technician). I may give them a try.

[muley]

Vaughn

No problem. You should be able to drive to Lakeside in 3rd. I used them (Tim) a month ago and was pleased with the service they provided

Otherwise I am on standby. It's a pretty straightforward job. Being an amateur gynaecologist helped

Jim

[TrevorB]

This sounds exactly what happened to me back in 2012/13 and I had fitted Bob Browns aluminium gear linkage kit.

Have you seen this post: viewtopic.php?f=129&t=27036

Might be and idea to get in touch and see if they are still available.


TrevorB

[Vaughnc]

Steve Williams (SW Lotus, Maidenhead) popped round this morning (amazing - a mechanic who drops in!) and confirmed what I suspected - a broken fore/aft cable.
So I ordered a cable pair from SJ Sportscars who have them in stock. Should arrive tomorrow. Their photo looks just like BCN's cables - could these be the same?
Shame I missed Bob Browns post though.

Next I need to see if I am capable of extracting the cables without losing the draw string up the tunnel and without swearing at the lack of spanner space behind the gearbox! Otherwise it will be driven round to Steve to help out.

I'll let you know what happens next!

Jim - are you free this week? Assuming the cables arrive tomorrow I'll aim to take Wed off work to fit the cables. Or Thur.

[Brit-Car-Nut]

Steve Williams (SW Lotus, Maidenhead) popped round this morning (amazing - a mechanic who drops in!) and confirmed what I suspected - a broken fore/aft cable.
So I ordered a cable pair from SJ Sportscars who have them in stock. Should arrive tomorrow. Their photo looks just like BCN's cables - could these be the same?

Sounds like Steve W. is a good guy!

Not even close, sorry. metal to metal isn't low friction and certainly not an improvement. They are definitely less expensive.

Shame I missed Bob Browns post though.

Next I need to see if I am capable of extracting the cables without losing the draw string up the tunnel and without swearing at the lack of spanner space behind the gearbox! Otherwise it will be driven round to Steve to help out.

I have found it easier to reach into the tunnel and hand them thru the firewall, past the mount to my helper. The string method usually get's tangled into the rear motor mount.

I'll let you know what happens next!

Jim - are you free this week? Assuming the cables arrive tomorrow I'll aim to take Wed off work to fit the cables. Or Thur.

[Vaughnc]

Sorry BCN - I did not intend to offend .
I can see on your website that your cables are very different indeed. Not sure what photo I found yesterday when I was first looking around that I confused with yours.

What do you mean metal to metal? All the cables I've seen in photos are the same basic design - all have a sheath with inner cable and metal ends (not that I've looked very closely however).

Anyway time is of the essence in this case due to the impending motor event, so "needs must".

[Brit-Car-Nut]

I didn't take offense, honest. I am amazed they sell any since their price isn't much less than Lotus's price for new S2 cables.

If you blow up their picture, you will see they are just metal. There are no bushings, sleeves or other lower friction inserts in the clevises.

It is a shame you weren't able to get the Bob B. cables for a similar price.

I am honestly not being offensive. They are nowhere as good as the S2 or A-B or even the original SE cables that were previously available.

I understand that my cables are expensive and take far too long to get to the UK, but that is what I am stuck with. I wanted my cables to do no harm to the car and be the last cables anyone needed to buy.

I also understood your deadline, so please understand, I know you did what you needed to do. It's too bad you didn't take you cables out to see if you could fix what you have.

[muley]

Hi Vaughn

You have a PM


Rgds

Jim

[Saltire]

And also one from me!

[Simon_P]

About ten years ago I changed the cables on an S2 with gear selection issues, it was the fitting on the end of the cable that broke. We were able to get a new end put on by a cable place and refit them.

There were some detailed instructions on here which I followed. From what I remember it wasn't difficult, but tests the patience. Use a camera to take pictures of what you can't see while you're arm is inside the tunnel.