Clutch replacement - LotusTalk

rstutts · 05-02-2009, 05:56 PM

I am going to upgrade my clutch soon, and was "considering" doing it myself

. Is there a thread on the steps of how to do it? Am I nuts for attempting this?
Thanks.
Rick

Dave · 05-02-2009, 06:00 PM

Quote:

Originally Posted by rstutts

I am going to upgrade my clutch soon, and was "considering" doing it myself

. Is there a thread on the steps of how to do it? Am I nuts for attempting this?
Thanks.
Rick

For what it's worth, replacing the clutch is ~10 hour job for an experienced mechanic.

VisualEchos · 05-02-2009, 08:22 PM

Wow, that bad? Hmmm...

andykeck · 05-02-2009, 08:43 PM

Quote:

Originally Posted by VisualEchos

Wow, that bad? Hmmm...

The only way to get clearance to pull the transaxle is to unbolt the engine and use a hoist to tilt the whole powertrain until it clears part of the rear subframe.

carl · 05-02-2009, 09:19 PM

the factory pays 5 hours. carl

rstutts · 05-03-2009, 07:45 AM

If there were specific instructions, like that came with my BWR s/c, I feel I could do it, possibly maybe! So there is no such thing on here anywhere?
Rick

montereyrob · 05-03-2009, 07:54 AM

I would love to see this too. I know it's hard to document a procedure step by step, but I'm an optimist.

VisualEchos · 05-03-2009, 07:55 AM

Quote:

Originally Posted by andykeck

The only way to get clearance to pull the transaxle is to unbolt the engine and use a hoist to tilt the whole powertrain until it clears part of the rear subframe.

Nice, I'm looking forward to it! Too bad I only have 13K on my clock.

Sergialized · 05-03-2009, 08:08 AM

I dit it.
With no mechanical experience other than bicycle...
I took a bunch of pictures and will eventually add them in a thread.
Serge

montereyrob · 05-03-2009, 08:13 AM

Quote:

Originally Posted by Sergialized

I dit it.
With no mechanical experience other than bicycle...
I took a bunch of pictures and will eventually add them in a thread.
Serge

Bavarian Motorist · 05-03-2009, 09:08 AM

Once you pull the rear clam and the underbody panels, you can pretty much access anything...

andykeck · 05-03-2009, 09:12 AM

Quote:

Originally Posted by Bavarian Motorist

Once you pull the rear clam and the underbody panels, you can pretty much access anything...

Yeah, but without unbolting, lifting and tilting the engine, there's not enough clearance to pull the transaxle off. No need to remove the clam. It's all in the service manual.

Eyelise · 05-03-2009, 12:13 PM

I thought someone mentioned a tech that allowed removal without pulling the engine.

I'm planning on trying this myself as well. I just pulled the clam. I'm doing the TVS kit, clutch and engine mounts all at the same time. Now to figure out the right sequence. Hmmm....

Quote:

Originally Posted by andykeck

Yeah, but without unbolting, lifting and tilting the engine, there's not enough clearance to pull the transaxle off. No need to remove the clam. It's all in the service manual.

rstutts · 05-04-2009, 07:05 PM

According to the Service Manual, it is done from underneath.

andykeck · 05-04-2009, 07:08 PM

Quote:

Originally Posted by Eyelise

I thought someone mentioned a tech that allowed removal without pulling the engine.

I'd like to know more about this if true.

There's only about an inch of clearance between the end of the transaxle housing and the subframe. You'd need a whole lot more than that.

uglyduck · 05-04-2009, 07:33 PM

I just did my clutch. I rented a garage with a lift, a trans jack and engine jack. It took two of us 11 hours. The manual is right on when it comes to the proceedure. There are only two tough parts, removing the inner left hand CV and getting ones hands in to reach all those unreachable bolts such as the starter. We has to unbolt the motor and support it with a jack then slide the trans. off the input shaft and rotate it 90 degrees to extract it. After we got the thing apart it was only two hours to put it all back together. I think the next time I have to replace the clutch it should be an 8-10 hour job. I don't know if I could have done the job on my garage floor

jlj3394 · 05-04-2009, 08:32 PM

Quote:

Originally Posted by carl

the factory pays 5 hours. carl

My mechanic did it in 5.5. Without using the manual and without having done one before.

Of course he also had a 20s Rolls in the next bay that he was rebuilding, a V12 BMW on the other side that he was doing a custom exhaust for, and a Chevelle he was looking to get 700HP out of across from it.

05-02-2009, 05:56 PM	#1 (permalink)
rstutts Registered User Join Date: Aug 2008 Location: Martin, TN Posts: 244	Clutch replacement I am going to upgrade my clutch soon, and was "considering" doing it myself . Is there a thread on the steps of how to do it? Am I nuts for attempting this? Thanks. Rick __________________ 2005 Solar Yellow Elise touring package, star shield, hard top, soft top, ACT HDSS clutch, Saikou Michi catch cans, LED tail lights and VF II, 288 whp () 2001 Green Toyota Tacoma, 4 x 4 2008 Red 5455 Massey Ferguson, 6 x 6, cab, ipod, GPS navigation, regular beer holder 2001 Yellow Cat D3G-LGP, custom made beer holder

05-02-2009, 08:22 PM	#3 (permalink)
VisualEchos Registered User Join Date: Aug 2006 Location: Missouri Posts: 1,015 Images: 3	Wow, that bad? Hmmm... __________________ My Car

05-02-2009, 09:19 PM	#5 (permalink)
carl Registered User Join Date: Oct 2005 Posts: 1,050	the factory pays 5 hours. carl __________________ User formerly known as 4carl

05-03-2009, 07:45 AM	#6 (permalink)
rstutts Registered User Join Date: Aug 2008 Location: Martin, TN Posts: 244	If there were specific instructions, like that came with my BWR s/c, I feel I could do it, possibly maybe! So there is no such thing on here anywhere? Rick __________________ 2005 Solar Yellow Elise touring package, star shield, hard top, soft top, ACT HDSS clutch, Saikou Michi catch cans, LED tail lights and VF II, 288 whp () 2001 Green Toyota Tacoma, 4 x 4 2008 Red 5455 Massey Ferguson, 6 x 6, cab, ipod, GPS navigation, regular beer holder 2001 Yellow Cat D3G-LGP, custom made beer holder

05-03-2009, 09:08 AM	#11 (permalink)
Bavarian Motorist Live to Drive Join Date: Nov 2006 Location: NYC/Westchester, NY Posts: 10,852	Once you pull the rear clam and the underbody panels, you can pretty much access anything... __________________ Be an alpha male. Drive a Lotus.

05-03-2009, 07:54 AM	#7 (permalink)
montereyrob Dignity, always dignity! Join Date: Aug 2008 Location: Monterey, CA Posts: 78	I would love to see this too. I know it's hard to document a procedure step by step, but I'm an optimist.

05-03-2009, 08:08 AM	#9 (permalink)
Sergialized Registered User Join Date: Sep 2006 Location: Quebec Posts: 61	I dit it. With no mechanical experience other than bicycle... I took a bunch of pictures and will eventually add them in a thread. Serge

05-04-2009, 07:05 PM	#14 (permalink)
rstutts Registered User Join Date: Aug 2008 Location: Martin, TN Posts: 244	According to the Service Manual, it is done from underneath. __________________ 2005 Solar Yellow Elise touring package, star shield, hard top, soft top, ACT HDSS clutch, Saikou Michi catch cans, LED tail lights and VF II, 288 whp () 2001 Green Toyota Tacoma, 4 x 4 2008 Red 5455 Massey Ferguson, 6 x 6, cab, ipod, GPS navigation, regular beer holder 2001 Yellow Cat D3G-LGP, custom made beer holder

05-04-2009, 07:33 PM	#16 (permalink)
uglyduck Registered User Join Date: Jun 2005 Location: Toronto Posts: 618	I just did my clutch. I rented a garage with a lift, a trans jack and engine jack. It took two of us 11 hours. The manual is right on when it comes to the proceedure. There are only two tough parts, removing the inner left hand CV and getting ones hands in to reach all those unreachable bolts such as the starter. We has to unbolt the motor and support it with a jack then slide the trans. off the input shaft and rotate it 90 degrees to extract it. After we got the thing apart it was only two hours to put it all back together. I think the next time I have to replace the clutch it should be an 8-10 hour job. I don't know if I could have done the job on my garage floor __________________ 2006 Tripoint SC with 10psi pulley and Aquamist, custom 2.5" free flowexhaust, FF headers, Decat, Ohlin's, track brace, custom carbon bits 1994 Caterham 7, R400 zetec conversion in progress

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