AB Shift Cables

[Fubar1764]

Ok, so Jeff, me, and a friend of ours, David, decide today's the day to install the cables. Everything goes well. We're making good progress. We're having a hard time getting the original Lotus cable bracket from off the engine, so we're waiting for Jeff to return with a smaller extension for a ratchet. I trip over the string that we had threaded. PHOOEY! David and I try to rethread. Wow, that's awfully low, but no matter. We thread the string it back "successfully."
Jeff gets back with the tool. We successfully remove the bracket. Life is good. We're thinking the operation so far has taken us a mere 3 hours. Nice indeed. We now try to thread the AB cables. Funny, they don't seem to poke through. We tug on the string. Nothing. We seem to be stuck somewhere. Blast, what could be wrong?!
We spend the next 2 hours trying to figure out how to thread the cables through. It's now dusk. Ok. Mrs. Fubar runs to the store to buy a couple of flashlights. We place the flashlight in the tunnel to see where the cables are SUPPOSED to come out. Got it. String onto wire coathanger, wire coathanger to thread through. Fabulous!
Oh pooh. I had to unbolt the bracket from the transmission to get the cables to thread through. Frustrating but not terminal. In go the east/west cable. Very nicely fit! E clip fits right into place. Now it's the fore/aft. And now it's the fore/aft. We're still trying to put the fore/aft into the shift thrower. After trying to fiddle with it for several minutes, we realize: the cable won't fit! The shift thrower assembly is too small, probably by about 3/1000th of an inch!!! GRR!
Ok, so tomorrow, we're going to increase the circumfurance of attachment for the cable and try again.
Oh but what great wrenching fun we had yesterday!!!

It's been nice second-wrenching with David. Next time, I might actually be ready to first-wrench!
And in complete irony, my wallet is lost somewhere in the tools, grease, and bits. It's somewhere in the car - I just don't know where!!!

In a few days, I'll post a comparison between the AB cables and the stock Lotus for all to gander.

[Fubar1764]

Well. everything's now sorted.
The bracket on the shifter for the shift cable was too small. I picked up a reamer ($65), plugged it into the drill, and expanded the hole. Derek (original poster of how to change the shift cables) suggested that I paint the bare metal parts with Rustoleum. Hmm. Good idea. So that had to sit for half a day.
After that, David and I attached the cables to the shifter. Naturally, one of the cotter clips snapped. Installed another one. We had to pull the cables from the engine side to slide the assembled shifter with attached cables into the tunnel. Not difficult, just easier with 2 people. After we had the shift gate assembled, "Grease. We forgot the lithium." Great. We undid the shifter, greased the ball joint. Everything gets put back into place.
David, being first wrench, adjusted the cables. Because we patterned the lengths to the original cables, we had the cables to within 1/8" of adjustment. Very nice! Attaching the cables to the transmission is NO TROUBLE at all. I fasten the cables, on goes the cotter clips. David adjusts. Voila! Shifter done.
I drive her while David drives the chase car. Shifting is magnificent! Shifting is crisp and not rubbery. I think this is on account that the rubber bushings on the shifter base were replaced with plastic bushings included in the AB cables. Also, the AB cables are built more robustly than the OEM Lotus. The robustness and the plastic bushings gives her a more positive feel to the shifter.
The shifting, already decent, is even smoother than before. I attribute this, again, to AB's more robust build. There's less wobble and possible variance in the cables' movements. The vibration that's transmitted into the shifter would be of a lower frequency, thus the shifting feels more clean. Again, more positive. The shifting feels fabulous. C'est magnifique!
Now the bad stuff. Shifting is still about 8inches fore/aft, 7inches cross. That's an awful lot of movement. I drove David's Acura Integra. 4inches f/a and 4inches cross. Not bad for OEM. The M100's shifter is well into the absurd territory. **sigh** C'est la vie.
So the coolant tank goes back on. The rest of the plumbing goes back on. Since we all know the coolant lines are byzantine and trap air pockets, I bled the coolant system. Yes, yes, overkill, but I'm not gonna make my mechanic replace a radiator unless he has to! So I bleed. After I bleed enough to convince myself that I've overdone it, I lightly hose off the area where the coolant bubbled out. Cool. Cleaned off the coolant. I go for a joy ride.
She stalls out after a few miles. WTF?! I suspect it's something having to do with my hosing down the engine. Got onto an electrical connection causing it to oxidize? That would suck. She starts up again! Never mind! I drive her for another half a mile, hit a bump, and she stalls! In working the cables, did an electrical connection come loose?! I coast into a museum parking lot. Thinking it's likely to be moisture, I let her spend the night away from home.
Armed with a can of brake cleaner, David, again first wrenching, and I try to start her. Jumper cables in place just to play it safe in terms of power drainage. We spray the brake cleaner at all the electrical leads and connections. Nothing. We spray onto the distributor. Starts right up!
Brake cleaner is not snake oil. It is the automotive elixer of health. Whatever problems one might have, brake cleaner will fix it. Ingition hesitation? Spray brake cleaner into the intake. Sap, tar, or grime on body? Brake cleaner. Need to remove moisture? Brake cleaner. And brake cleaner's great for brakes too!

Now, back to happy Elaning!
Cheers!
Jack

[Fubar1764]

Out for a nice cruise this evening.
Shift into first. Nice. Second. Nice. Third. Traffic light. Into neutral. Stop. Shift to first. Nic**PING** It's in neutral! Ok. This could be bad. This happens a few other times. Hmm. Every now and then (approx 30%), the shifter will pop from first into neutral as the clutch is being let out. When this happens, I also can't get into third until I align the cables by going into second or fourth. I suspect it's a simple cable adjustment.
Now if the shifter popped out of gear while engaged, well, that would be trouble. Bad synchro.
I pop the hood and whip out a flashlight. With someone shifting, I looked. Looks like the fore/aft cable was adjusted too short. Tomorrow, I'm going to let out the cable 1/4inch. While I'm there, I'll probably adjust the cross 1/32inch as well to see if I get better feel. Report findings as I find 'em.

[Fubar1764]

Well, another day, another bit of coolant on the ground. Since yesterday, the fore/aft started to pop out of first gear nearly every time. Ah, the stretching of the cables. Good, now I can kill two birds with one stone. I went to my mechanic today to get my oil changed. Easy job. And boy were they impressed by the spiffy oil cap! Brian, you rock!
They change the oil and I get busy with the cables. I adjusted fore/aft the 1/4inch. While I'm adjusting, one of the mechanics says, "I'll do that for you." "Oh, that's ok, I'm actually having fun." "It's painful to watch you." "Yes, I know it's painful to watch incompetence, huh?"
More brake cleaner all over. Put the coolant tank back in place. Add water, and I let her rip. Very nice! No popping of the shifter. But wait, after some time, I sometimes have trouble getting into 3rd. Uh-oh. Looks like the cross cable's stretched as well. I'll give this one a few days to stretch out a bit more before adjusting.
The only annoying part of the operation is the removal of the coolant tank. Adjustments of the cable really couldn't be more simple. A few turns of the wrench that's included in the kit to break the tension, a few turns of the securing nut by hand. Tighten the other nut, and you're done. I'm thoroughly impressed with the workmanship and thought that went into these cables. Thanks Alan Betts & Will B!

[Fubar1764]

Awesome. Simply awesome. I'm having some consistent issues with shifting into reverse. I believe it might be a crossgate adjustment. I'm giving the cables a bit more stretching then adjust. Might be a while. I'll report when something is reportable.
Rock on!

[nitroman]

Fubar, this stretching of the cables bit is a fallacy. Just move the overflow tank out of the way once; then adjust & check, adjust & check, ad-infinitum - all with the engine off. When everything engages & shifts smoothly, reassemble & you are done.

[Fubar1764]

Cool! If that's the case, then a minor adjustment. I'm not getting stuck in any gear, not getting popped out of any gear either. . .no, no synchro burning up!
Glad you out and about Nitro! Don't wave that bloody shirt too much, eh?

[nitroman]

Your Flail of God struck me in the back dude. I'm gonna sue. You know a good lawyer?

Seriously, it's weird but nice now on post-surgery day 3 not to have any of the old symptoms, but to have all that otherwise OK muscle cut through to get to the problem. Now I can walk around fine, I just can't bend over (stretches-out the sliced-through muscle).

I can now say I know what it feels like to be stabbed! (with a 1.5" wide knife, and however long it takes to get from your back to the front of your spine)

[Fubar1764]

Oh yes. I was aiming for someone else. Collateral damage. My apologies. God's old school - no laser guided spears or sling missiles. God's military spending's been down and stretched thin besides. Angels want that whole perscription drug thing, you know. . . Heaven's getting soft if you ask me.

Seriously. If you want those post-op films looked over, send 'em to me.

[RFly2Dive]

Fubar,
It sounds like the AB shifter cable upgrade was worthwhile...I am sure there is a link here somewhere on how to contact/order them from the web but as of now I have not found it... Can you give me a heads up as far as how to get in contact with them???
Thanks
Ralph

[Fubar1764]

Hey Ralph!
Good to hear from you again! The cables are fairly costly: $470 shipped. A good replacement at a more reasonable price is the Isuzu, which is quite a bit less than the OE Lotus. Just something to consider.
If you go with the ABMotorsports cables, you'll pleasantly surprised at the build quality and the subsequent feel of the shifter. Since I won't be selling my M100 for another 30 or 40 years, I can justify the investment and want to enjoy the super-duper shifter now.
I picked my cables up from our friend, WillB. He's put in the order and has ABMotorsports ship them. It arrives approximately a week later. . .sooner, if your local post office doesn't botch up the delivery like mine did. WillB is on holiday until later this month. I'd zap him a PM in a few weeks. I'll go ahead and email him to expect your PM.
Cheers!
Jack

[Monty]

Looks like i`m going to have a read up on this thread and the manual as i was leaving a meet last nite in bolton only got round the corner and i couldn`t change gear so Pinky had to be recovered by the RAC. Anyways i`ve had a look at the gear cables on the gearbox end and were one of them meets the metal bracket the plastic part as broken were the clip holds it in position (see pics). As i`m short of dosh i`m thinking of using the cable out of Pinky 1 but if it turns out to be a B**tard of a job then i`ll get the AB cables.

[Fubar1764]

Monty, I highly recommend the ABMotorsports cables, as I'm sure you can tell. The fit of the ABM cables is truly extraordinary. I would encourage you to save up for the ABM as their fitment and their build quality are truly magnificent.
Either way, you'll find the operation will take approximately 3 hours given your talents. You'll need a 10mm socket as well as a 13mm socket. Also pick up a universal socket joint. Wear leather gloves when you're in the engine bay as you're "breaking" the lock of the bolts or when you're in the final tightening of the bolts. Remember the string and DON'T TRIP OVER IT! Match up the cables and where they're adjusted at the ends, and you'll save some time on the adjustments at the end.
The pins that hold the cables in place a bit different from those of the E clips that held mine. Could be just another inconsistency in Lotus manufacture.
Post up if I can help.
Oh yeah, get yourself some cotter pins - you're likely to snap the smaller ones connecting the cables to the shifter.
Best of luck!

[Monty]

I`ve not even read up on it and i`ve already removes the cables from Pinky 1, luv to get the AB`s but can`t quite afford them at the mo. So i`ve noted u`r tips and i`m about to start fitting them to Pinky

[Monty]

well Pinky`s back on the road, glad i did it myself cost me nothing and just wonder how much Lotus would charge for fitting those cables Think it`s the fore & after cable i`ve replaced, the one i removed had a plastic fitting where it met the gear stick assembly and not adjustable, the one i replaced it with (from pink 1) had the metal fitting and was adjustable is this the uprated version? Anyways seem to have all gears and need to invest in AB cables.

[Fubar1764]

Good show! Had you gone to Lotus, the recommended time for the repair is 8hrs. Well done, mate!

[Alan_Betts]

It took six months to get our gear cables exactly right.

You can see pictures at:

http://www.abmotosport.com/Elan_products.html

The hardest part was getting the transmission end bracket spot on.

It took eight versions to get it just right and the transmission end bracket is now CAD designed and laser cut to ensure consistency of manufacture.

The testing process included on track testing by a well known Lotus employee. The cables survived unscathed and with the thumbs up.

Will B is the man if you want a set.

My favourite part of the gear cables is the purpose designed spanners supplied with them. When you fit the cables you will understand why we made the spanners.

[valimar]

Hey Ralph!
Good to hear from you again! The cables are fairly costly: $470 shipped. A good replacement at a more reasonable price is the Isuzu, which is quite a bit less than the OE Lotus. Just something to consider.
If you go with the ABMotorsports cables, you'll pleasantly surprised at the build quality and the subsequent feel of the shifter. Since I won't be selling my M100 for another 30 or 40 years, I can justify the investment and want to enjoy the super-duper shifter now.
I picked my cables up from our friend, WillB. He's put in the order and has ABMotorsports ship them. It arrives approximately a week later. . .sooner, if your local post office doesn't botch up the delivery like mine did. WillB is on holiday until later this month. I'd zap him a PM in a few weeks. I'll go ahead and email him to expect your PM.
Cheers!
Jack

Hello Jack,
I want to order the gear cables for my M100 from ABMotorsport but they don't answer to my e-mails! Can you please tell me how I can contact WillB for ordering this item?
Best regards and thank you!
Rodrigo

[Mike_H]

Valimar,
try this link http://cgi.ebay.co.uk/Lotus-Elan-M100-S ... dZViewItem

Mike.

[valimar]

Valimar,
try this link http://cgi.ebay.co.uk/Lotus-Elan-M100-S ... dZViewItem

Mike.

Is that some kind of joke or or do you use the showercape to change gears Here in South Portugal we don't have much rain...
Rodrigo