Shift structure flex, loose rivet

[wings & wheels]

File this as another thing to look out for....

2005 Elise 4,400mi

The blind rivets holding the fabricated sheet metal shift structure assembly together can work loose causing it to flex significantly, especially when moving the lever laterally or selecting 1, 3 & 5. The problem rivets are located on the upper, forward, right side of the structure.

I was never completely satisfied with the shift feel of the Elise. It was good, but was never as crisp or as quiet as I thought it should be. I thought part of this was coming off an S2000 which has one of the best feeling transmissions I've ever experienced. Also, the reverse collar would not return on its own.

I took the console off to install the new one and leather knob from the Trim Shop (excellent work by Lotus BTW) and a spacer to cure some of the flex when I noticed that the entire structure was visibly flexing and making a clicking noise when I moved the lever through the pattern. The upper blind rivet on the forward right part of the assembly was working allowing the forward part of the structure to flex. I drilled out the failed rivet, opened the hole a minimal amount, then installed a new 3/16 blind rivet. I used a standard automotive "pop" rivet, but there is a fair amount of twist and shear force on that part of the structure, so if it loosens again, I will install an aircraft "cherry" rivet. Shift feel is improved and quieter.

As for the reverse lockout, the plastic collar and shift lever had some gunk on it, almost like old grease. Cleaning this and a little bit of silicone grease and the collar functions properly.

The fun of owning a hand built niche car.

Something to check.

Rgds, w