Lotus Elan Central

by **Hegg** » Tue 16.01.2007, 04:06

Alright, so I got my new flywheel and clutch all installed and the whole car put back together after 14 weeks of sitting. Went to start it and BAM, started up beautifully and perfectly. Went to try the clutch, and NO, I can't get into any gear. Trying reverse grinds the gears, but the rest won't even try to go in.

So, I'm fairly confident that this is a cable adjustment problem somehow. It's like the pedal isn't pushing far enough - the stroke is too short or something. I've adjusted the cable adjustment mechanism to the farthest down the threads I can get it, and I even had to pry the clutch release arm up a few mm to get the adjustment cable back on, and still no workie. The pedal height is 6.5 inches or so, and the instructions say the pedal height should be 7.5 - 7.75 inches, but I can't find any way to adjust the pedal height.

The clutch release lever thingy can be pulled maybe 2 inches before it touches the pressure plate (and therefore can't pull it anymore). So, is there another adjustment I'm missing?

What I'm most worried about, of course, is that the new pressure plate and/or clutch disc and/or flywheel were incorrect. Everything looked like it was a perfect match from what I could tell. I'm kicking myself for not taking exact measurements of everything - I really wish I had. Is it possible that my pressure plate is too "thin" - so it's too far from my release bearing? It seems like I shouldn't have to adjust the clutch cable that much for it to reach the pressure plate. Could the clutch disc be too thick?

I'm just plain bummed right now. It took so much time and effort to get to this point, and now I'm stuck without a car still. I think I'll tow it to a transmission place and have them change it out if needed. I can't do it again right now - I'm burned out.

Please let me know if anything obvious sticks out. I got the Centerforce clutch kit, part #DF586041. It says it's for the 4XE1-T engine, which is what the Elan has, right? It fits the Isuzu Impulse.

Thanks for listening...

by **Monty** » Tue 16.01.2007, 12:20

I`m sure David jt got a clutch from Centerforce, might be worth dropping him a PM

I remember Sy ( 4 puk clutch) saying something about spacers being fitted on the clutch cable, saying that Dico fitted the same one as Sy and had no problems and didn`t even make any adjustments

The only thing i can think of is to prise the clutch fork over with a crow bar and have one someone else in side to see if u can get it in to gear (obviously with engine not running) if u get in to gear try fitting spacers but it`s not ideal

by **Sy V** » Tue 16.01.2007, 14:22

Monty wrote:I remember Sy ( 4 puk clutch) saying something about spacers being fitted on the clutch cable,

Did I?...I don't remember that (now I really am worried about my memory), and it's six puck clutch.

by **Monty** » Tue 16.01.2007, 18:21

Maybe i`m wrong then

pop u`r bonnet u`ll soon find out lol.

by **Hegg** » Tue 16.01.2007, 18:31

Monty wrote:The only thing i can think of is to prise the clutch fork over with a crow bar and have one someone else in side to see if u can get it in to gear (obviously with engine not running) if u get in to gear try fitting spacers but it's not ideal

I can change gears just lovely when the car is not running. Just when it's running, the clutch doesn't disengage far enough to let me switch gears.

Thanks for the other information. My dad is a machinist and I was thinking of having him make some kind of spacer or something. I just don't think that's the problem though.... I don't know. The pedal just isn't pushing far enough.

by **gmacz** » Tue 16.01.2007, 19:30

Have you fitted the friction disc correctly.It can be fitted the wrong way around and still fit.It usually has flywheel side written on it.As already mentioned push down the clutch lever and if it does not travel the full distance get someone to lever it to it's full extent and then try changing gear.Yours Gmacz

by **Hegg** » Tue 16.01.2007, 19:33

I triple-checked putting the friction disc on the right way (flywheel side toward the flywheel), but of course I could have still done it wrong.

So with someone prying the clutch lever the whole distance, I'm guessing I want to do that while the engine is running and see if it'll go in? And that would basically prove that everything is "assembled correctly" and that it's just an adjustment issue, right?

Thanks again for all the advice and help.

by **gmacz** » Tue 16.01.2007, 19:41

Sit in car, handbrake on, foot brake on, dip the clutch with engine running and get someone to make sure the lever is going it's full travel.If it is not, get him to lever it to it's fullest extent and then try changing gear.This will tell you if you have a cable/pedal adjustment problem. Yours Gmacz

by **Hegg** » Tue 16.01.2007, 20:59

Thanks for the clarification. We'll see what I can find out tonight when I get home.

by **Monty** » Tue 16.01.2007, 23:19

don`t forget u could always jack up the front so the front wheels are of the ground to make sure u don`t go straight through the garage door LOL don`t forget to use axle stands or bricks and a block of wood.

by **Dico** » Wed 17.01.2007, 16:44

Sorry to here the bad news Hegg.

Like Monty said, Sy and Gerome both had spacers of some description fitted wereas my went in without any adjustments. Different clutch to yours though I think so maybe not relevant?

by **Hegg** » Thu 18.01.2007, 04:15

If Sy or Gerome are reading - can you describe what/how you did the spacers?

by **Sy V** » Thu 18.01.2007, 06:42

Hegg, I have no spacers.

Lotus Elan Central

Is there a trick to adjusting the clutch pedal?

Is there a trick to adjusting the clutch pedal?

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