Broken Gear Linkage/Cable

[Vaughnc]

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.

Thanks BCN - you've been super helpful! I ordered the SJ cables assuming I need them and before knowing for certain what the problem is simply because time is short. I dont mind spending a bit as insurance! Its a shame I did not call Bell & Coville until today. They say Lotus have the cables in stock for delivery tomorrow - at around 500 plus vat + delivery I believe. Not given up on the Bob B cables - just no reply yet.

[Brit-Car-Nut]

From Lotus, You can just buy the one cable that you need. The S2 cables have been quite dependable. Figure out what you need and then get enough to fix your problem.

[Vaughnc]

As of tonight I have manged to disconnect both cables from the gearbox - awkward to get to and turn the securing nuts but finally did it! I was ready to cut some 22mm spanners short but did not need to in the end. A combination of WD40, a plumbers adjustable basin wrench (it has a pivoting and adjustable head) plus a short adjustable spanner did the trick. One cable moves freely, one does not. Will be withdrawing them thru the tunnel tomorrow and then I hope to identify what is wrong.

[Brit-Car-Nut]

Sounds like progress.

My cable kits all come with a pair of short jam nut wrenches. Maybe someone close to you will offer to loan theirs to you.

Wrenches003.jpg

These are the raw parts after laser cutting. They are zinc plated in the next step.

AB Cable kits (Singapore) also included wrenches.

[muley]

As of tonight I have manged to disconnect both cables from the gearbox - awkward to get to and turn the securing nuts but finally did it! I was ready to cut some 22mm spanners short but did not need to in the end. A combination of WD40, a plumbers adjustable basin wrench (it has a pivoting and adjustable head) plus a short adjustable spanner did the trick. One cable moves freely, one does not. Will be withdrawing them thru the tunnel tomorrow and then I hope to identify what is wrong.

Whoops! I should have told you about the basin spanner 'trick' I'll leave mine at home today. I do have the AB spanner somewhere, I should try and dig it out. See you later all being well.

Rgds

Jim

[Vaughnc]

At last all is finished!

The problem was indeed a snapped cable.

The gear-lever assembly was dismantled to clean and re-grease. Hopefully my helper Jim (Muley) will post the photo he took if anyone is interested.

Adjusting the new cables was somewhat painful though. After 1st fitting all seemed OK until we found we could not select 1st/2nd gear. Crossgate cable was not pushing the relevant gearbox lever far enough. A bit of adjustment and it worked reluctantly. Disconnected it all again to re-adjust and then lost the R-pin at the gear stick end into the tunnel. Had to wait 'til morning to get a replacement. Ran the car yesterday to/from work but still not happy - gear shift was a bit "graunchy". Disconnected and adjusted again today - now much better. A little stiff but not at all bad. Hopefully it will loosen up in time:)

Along the way I had to replace a fixing that fell apart whilst moving vacuum pipes to create space. Someone might find the fix useful. The Lotus has a few nuts embedded in a rubber grommet. These perish and fall apart - useless when you try to reconnect an item. If you can't find the same type of fixing you can make one up. I have used a new rubber grommet, inserted a plastic plasterboard/stud wall fixing and bingo a new secure connection! I have previously used this for the Boost Gauge sender and the aforesaid vacuum pipe. The fixings are more secure than the ones they replaced.

I'll attach photos when I figure out how to do that on this forum!

Now I just need to look into the latest problem - a feint Battery telltale light. That's another bit or research or post I think

Finally - many thanks to all who offered help/parts/advice. I would have gone mad without your assitance!

[muley]

rsz_img_20181017_131946748.jpg

Hi Vaughn

Happy to have been of assistance. Couple of pics here. Thanks for the coffee and lunch!

[Rambo]

Now I just need to look into the latest problem - a feint Battery telltale light. That's another bit or research or post I think

My money's on the alternator or the battery has given up

[John_W]

Well done for getting it fixed. Good old muley. (No offence with the “old”. )

A few questions, just for clarification:

• Where was the break in the original cable?
• Was it definitely an S2 cable that broke?
• Why did you have to dismantle your gearshift assembly?
• How is the feel of gearshift now? (The attachment of the replacement cables to the gearbox selector mechanism looks a bit basic and not exactly low-friction.)

John