Broke my gears

Drivetrain problems

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Broke my gears

Postby malbon » Wed 26.07.2006, 07:36

I was wondering if it was too good to be true. 4 months of trouble free Lotus ownership.

Last night I was giving it beans in 1st gear, went to catch 2nd and missed it and the gate went all mushy. I can still get all the gears fine but 2nd and 4th dont feel very positive and the throw seems to have increased :cry:

When I had it serviced the chap said he was surprised to see I was still on my original gear cables. Have I snapped one of these or something ?

Is it just the gear linkage do you reckon - bushes ? Am I able to get upgraded ones and a short shifter to also reduce the throw?

Cheers and TIA

Jon
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Postby chris.t » Wed 26.07.2006, 08:50

yes i'm afraid over zealous gear changes will result in the cables breaking. i believe there is an upgrade kit out there which i'm sure some kind (WillB) person will help you with.
Could the 'Hokey-Cokey' actually be what it's all about?
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Postby Enright » Wed 26.07.2006, 09:36

You MAY be lucky.

If you had snapped the cable then you wouldn't be able to get any gears and the throw would not just be mushy - there would be no resistance at all!

It's possible that you could have over-stressed the adjustment mechanism, which is incorporated into the gearbox end of the cable, and may now be slipping.

Remove your top intake pipe and move your coolant reservoir out of the way, then you can see the cable ends on the top of the gearbox, and following them backwards, a bracket where the cable shroud ends are located.

The offending cable is likely to be the lower one - this controls fore/aft movement. If the big E clip which secures the cable to the bracket is missing or there is no plastic there for it to grip (compare it to the end of the other cable), then you'll know that it's broken.

Otherwise, get someone to sit in the car and move the gear lever backwards and forwards. If the centre bit moves in and out of the shroud, then it has simply come loose, and you might be able to lock it back in place by turning the knurled part behind the bracket.

(All of the above will become an awful lot clearer once you can see it!)


You can replace one cable at a cost of about £150 inc VAT & P&P for an OEM one. But you have to remove both to do the job, and might damage the other in the process - the plastic hardens and becomes brittle over time.
The alternative is that by spending less than £100 more you could get the vastly superior AB Motorsport set via WillB, which apparently make it feel like no cables are involved at all!


As for short throw kits, IsuzuPerformance.com used to do some which replace the original selector box, but they are long since discontinued.
An alternative may be to fit an extension to the arm below the gear lever.
This was recently discussed in this thread (which also includes drawings of all I described above).
Striking fear into the hearts of duplicate posts everywhere...! :P

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Neil ;-)
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Postby Monty » Wed 26.07.2006, 11:48

The cable it self doesn`t break, as neil says it`s the plastic part that fits through the bracket that breaks.

I`ve got a set off stock SE gear cables u can have for £50 as i replaced mine with AB`s which i bought direct
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Postby malbon » Wed 26.07.2006, 12:01

Cheers for the replies guys. Ill get the garage to take it apart later and have a look whats broke.

Monty - might take you up on that. Ill post later on with the dreaded verdict :shock:
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Postby malbon » Tue 01.08.2006, 09:11

Ah bugger, took it to my local garage today to have a look - Neil, thanks for the pointers - I printed your post to show them. First I end up losing Reverse and then 2 and 4 go. There is a lot of movement know and looks like its totally fubar'd.

Apparently a piece of plastic has snapped on one of the cables and a circlip has gone missing ??

Anyway the result is that I will probably need a new set of cables.

I dont think im going to put OEM ones and even though - shock horror - i might be selling the car :shock: I think im going to go along the AB cable route with WillB. I want the car to be right when sold after all.

Does anyone know how long it takes to fit these. Is there anyone on here in the Midlands who can do it for me for some beer tokens ? or am i best just taking it to the local garage. They looked a bit scared by the shoe horned engine. How long should it take them ?

Cheers

Jon
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Postby TStevens » Tue 01.08.2006, 09:34

Stevo knocked a set out on Stefs car in Donington car park, took about 1hr 30?

I think theres some pictures around here of Stevo elbow deep in Stefs tunnel.
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Postby Enright » Tue 01.08.2006, 10:26

I can do it - I can already picture exactly the problem you have.
Would prefer to do it on my premises though just in case of unforeseen events/having all tools I might need to hand.
If you've got 2nd & 4th and can get to mine, I don't mind spending a Saturday afternoon on it (if it's dry).
Let me know when the cables arrive and we can arrange something.

So, now that's sorted, who's going to be the first to make any obvious comments about Stevo being elbow deep in Stef's tunnel?!? :lol:
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Postby TStevens » Tue 01.08.2006, 11:58

nice offer Enright... :)

Be glad you have a semi-drivable car, mine got stuck in 3rd so was a right pain, had to get it transported home, and transported to the repair place.
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Postby Gary » Tue 01.08.2006, 18:16

Enright13 wrote:So, now that's sorted, who's going to be the first to make any obvious comments about Stevo being elbow deep in Stef's tunnel?!? :lol:


He's either got short arms or it's a big tunnel :lol:
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