Lights Popping Out - LotusTalk

JMA · 07-08-2007, 08:32 AM

Last night I hit a pothole on the wonderful Golden State Freeway near Gorman (on the way back from Skyvue's Stargazing). Wham! and the left directional light popped out. Second time this happened. Anyone else have this happen? Any way to keep these things in their place? First time was in a parking lot when I lightly bumped the concrete tire stop at 2 mph. That clam must be very flexible.

GaryD · 07-08-2007, 08:39 AM

http://www.elisetalk.com/forums/showthread.php?t=42382

ace10 · 07-08-2007, 08:42 AM

a piece (or two) of painters tape will keep the assembly in-place at the track or autoX. probably not so good on the street.
i think there are a bunch of threads with this same complaint and maybe even a solution or two.

Baysailor · 07-08-2007, 10:31 AM

I found that on both my clams (original one and a new one I purchased after damaging the first) that my indicator housing didn't "click-in" completely. The little tabs didn't fully catch. I took my dremel and fine tuned the fit by grinding the area on the clam that "catches" the tab. I was able to get a great fit, very positive latch and never have had a problem since. It was a very noticable improvement in the latching. You definitely want to work slowly with this and think about the fitment as you go. Too much and you make your problem worse.

In the event you do go too far with it, you can always build back up any surfaces with some two part epoxy and some additives to thicken it.

Ken Wright · 07-08-2007, 02:25 PM

My passenger side popped out recently while I was on a smooth interstate @ 80 (legal).

I've got a new one but haven't put it in. The old one failed at the front clip. Some of the clip remained so while I had to wait on it's replacement I used plastic coated wire to fasten it to the grill of my Exige. To anchor it I drilled a hole in the part of the tab that remained. It will never come out now and it is easy to remove. The new one can wait on the shelf.

ken

Keeper · 07-08-2007, 02:31 PM

Yes, the turn signals popping out is a known problem and there is a fix. I'm surprised I don't have the link. I'll post it if I find it before someone else does.

. . . It's a warranty item . . .

. . . possible fix by grinding away some of the clam?!

http://www.elisetalk.com/forums/show...3&postcount=16

. . . Service bulletin info and fix pics:

http://www.elisetalk.com/forums/show...9&postcount=26

. . . OK, that's all I could find searching thread titles for "signal"

I'll add this thread to the uberpost with the next major update.

EburgE · 07-08-2007, 02:48 PM

Mine popped out once. Dealer fixed it without hassle.

shay2nak · 07-09-2007, 07:53 PM

I can't even get mine out on purpose to change the bulb.

sandsmuseum · 07-11-2007, 06:39 AM

This has happened several times to me. I had the light replaced under warranty twice before I decided to do the fix myself.

My first fix is shown here:

http://www.sandsmuseum.com/cars/elis...catorlens.html

Later I just drilled a small hole in the left over tab and hooked one of the small bungee cords into the hole. Then feed the other end into the hole and hook any place handy. Now the lens can be pulled out when needed, just by lifting the front of the lens...

Lotus liked my fix so much they decided to implement something similar in the new front end. They upgraded my design to use an O ring instead of a bungee cord. (I fibbed about Lotus liking my design, but not about Lotus upgrading the design to use an O ring. Can anyone verify this on a new rear bumpered car?)

Michael

Edited to add new Lotus design comment

perryeyges · 07-11-2007, 06:47 AM

JMA, it's funny that your avatar shows a car in the corkscrew. I have heard of more than one 996 Porsche that has had a headlight pop out under the torsional flex exerted on the chassis in the corkscrew. When a 996 headlamp assembly pops out it will cost you up to $1,600 to replace the scraped up unit.

OUCH!

Surferjer · 07-11-2007, 07:26 AM

Mine popped out on a cone direct hit at 60 MPH. I was able to simply pop it back in and haven't had an issue since then. Here's a pic. My daughter is saying "Ummmm, Dad?" nd I'm replying "Shutup Jess, I know!" I completed the run and fixed the light in time for the next run.

LARRY · 07-11-2007, 07:47 AM

A small amount of automotive glue/goop is holding mine back in until I next see the dealer.

A little on each side of the turn signal holder, and hold it on there for a few minutes.

Works. Stays put.

shay2nak · 07-11-2007, 09:39 AM

all they got to do is put a screw up there where the access hole is. Unscrew and remove...how easy is that?

JMA · 07-12-2007, 10:06 AM

Quote:

Originally Posted by perryeyges

JMA, it's funny that your avatar shows a car in the corkscrew. I have heard of more than one 996 Porsche that has had a headlight pop out under the torsional flex exerted on the chassis in the corkscrew. When a 996 headlamp assembly pops out it will cost you up to $1,600 to replace the scraped up unit.

OUCH!

Luckily, my Lotus 51 (Formula Ford) didn't have lights at Monterey, or they probably would have popped out. I almost did--what an event, the 1995 Monterey Historics tribute to Lotus. Hope they do it again.

AttAkker · 08-03-2007, 09:58 PM

Both have mine have popped out in just 2 months. I messed with a few ideas, but finally came up with this fix. Here it is

Baysailor · 08-04-2007, 05:31 AM

Quote:

Originally Posted by AttAkker

Both have mine have popped out in just 2 months. I messed with a few ideas, but finally came up with this fix. Here it is

I like the use of the springs, nice idea!

RoadDad · 08-04-2007, 05:46 AM

how about a very small bunge cord instead of the spring to save weight?

my '07 elise has a small retaining bunge cord traveling cross ways that the clip hooks under before clipping under the clam. Don't know if this is a fix by Lotus or if the earlier models also have this. It holds very tightly and makes it even a bit harder to get the turn signal out.

AttAkker · 08-04-2007, 02:09 PM

The spring weighs practically nothing and it's cleaner than just a bungee IMHO. Also they tend to stretch over time wheras the spring should have long life. Whatever works best for everyone'd taste. I was just offering up what I came up with.

JMA · 08-05-2007, 09:12 AM

Thanks for all the advice. I took the car back to the dealer and he replaced just the surrounds. Only have about 50 miles on it since then (been out of town), but time will tell. The springs/bungee cords sound good, so may try that if they come out again. Now I carry some black electrical tape and scissors, just in case. Starting to build up a supply of repair items like I do with my 1954 MG TF. Lots of roadside restorations there, too. Thanks again.

07-08-2007, 08:32 AM	#1 (permalink)
JMA Love that Lotus Join Date: Feb 2007 Location: Tujunga, CA Posts: 207	Lights Popping Out Last night I hit a pothole on the wonderful Golden State Freeway near Gorman (on the way back from Skyvue's Stargazing). Wham! and the left directional light popped out. Second time this happened. Anyone else have this happen? Any way to keep these things in their place? First time was in a parking lot when I lightly bumped the concrete tire stop at 2 mph. That clam must be very flexible. __________________ Jack-'06 Elise BRG

07-08-2007, 08:42 AM	#3 (permalink)
ace10 -30- Join Date: Jun 2006 Posts: 4,449 Images: 35	a piece (or two) of painters tape will keep the assembly in-place at the track or autoX. probably not so good on the street. i think there are a bunch of threads with this same complaint and maybe even a solution or two. __________________ 2007 Exige S, Storm Ti. Sport, Track and TC.Plus: Multivex Mirrors, S111 Deltabrace, Sparco 6Pt harnesses (w/Ti Dave's Antisub belt mount), I/O Port video mount, Snorkel delete, Shims out, Rearview Mirror delete, 2Bular 7X18, Pagid RS42's, Saiku Michi catch can and, of course, blingy carpet buttons. 08 M-B ML320 cdi, 08 Toyota Tundra SR5 5.7, 06 M-B E320 cdi, 02 Lexus LX470, 97 Bobcat 751C The Red Pill Ignore Me *Be sure too save your IL before browsing away

07-08-2007, 10:31 AM	#4 (permalink)
Baysailor Registered User Join Date: Jul 2005 Location: Richmond, VA Posts: 1,157	I found that on both my clams (original one and a new one I purchased after damaging the first) that my indicator housing didn't "click-in" completely. The little tabs didn't fully catch. I took my dremel and fine tuned the fit by grinding the area on the clam that "catches" the tab. I was able to get a great fit, very positive latch and never have had a problem since. It was a very noticable improvement in the latching. You definitely want to work slowly with this and think about the fitment as you go. Too much and you make your problem worse. In the event you do go too far with it, you can always build back up any surfaces with some two part epoxy and some additives to thicken it. __________________ 2006 Lotus Elise - Solar Yellow, HT, LSS, LSD/TC, Touring, StarShield, S111 RTDbrace, S111 microMirror, S111 Carpet Buttons, Painted A/C Surround, CF Center Console, Nitron S/A, Tempest BAB26-12 AGM Battery, Fujita Intake, Top Speed Pro 1 Exhaust, 4Tress Harness Bar, 6000k 35w HID kit, Moroso Oil Pan, Plinthless front clam, Team Dynamics Pro Race 1.2 Wheels w/ RE01-R's for street use, Heater Core By-Pass, Shifter Reinforcement, LETSLA v2 Shift Kit

07-08-2007, 02:25 PM	#5 (permalink)
Ken Wright Registered User Join Date: Jul 2006 Posts: 475	My passenger side popped out recently while I was on a smooth interstate @ 80 (legal). I've got a new one but haven't put it in. The old one failed at the front clip. Some of the clip remained so while I had to wait on it's replacement I used plastic coated wire to fasten it to the grill of my Exige. To anchor it I drilled a hole in the part of the tab that remained. It will never come out now and it is easy to remove. The new one can wait on the shelf. ken __________________ All torque, no traction...Exige S. Real sports cars don't have A/C!

07-08-2007, 02:31 PM	#6 (permalink)
Keeper Probably Lurking Join Date: Nov 2003 Location: North of Boston Posts: 2,152	Yes, the turn signals popping out is a known problem and there is a fix. I'm surprised I don't have the link. I'll post it if I find it before someone else does. . . . It's a warranty item . . . . . . possible fix by grinding away some of the clam?! http://www.elisetalk.com/forums/show...3&postcount=16 . . . Service bulletin info and fix pics: http://www.elisetalk.com/forums/show...9&postcount=26 . . . OK, that's all I could find searching thread titles for "signal" I'll add this thread to the uberpost with the next major update. __________________ -Shawn (2005 Lotus Econoxotic) Uberpost -- things owners should know - common problems/fixes - rattles, squeaks, noises - read the manual - good ideas? - maintenance - mods - reference - abbreviations Last edited by Keeper : 07-08-2007 at 02:42 PM.

07-08-2007, 08:39 AM	#2 (permalink)
GaryD Registered User Join Date: Feb 2005 Location: Baltimore, MD Posts: 466	http://www.elisetalk.com/forums/showthread.php?t=42382

07-08-2007, 02:48 PM	#7 (permalink)
EburgE Super 7 Owner In Training Join Date: Nov 2005 Location: Eldersburg, MD Posts: 2,416	Mine popped out once. Dealer fixed it without hassle. __________________ '05 Lotus Elise '07 Caterham Seven www.hals7.com

07-09-2007, 07:53 PM	#8 (permalink)
shay2nak GGM ENFORCER Join Date: Dec 2003 Location: Land of da 1000 Oaks, CA Posts: 14,344	I can't even get mine out on purpose to change the bulb. __________________ save ~10 lbs gain 1 hp EQ: Y=(190X) / (1984-X) where Y is (HP) and X is (lbs) '07 EXIGE S * MY CAR ** VIDEOS! '08 ACURA TSX 6-speed http://www.makeNYNYagain.com

07-11-2007, 06:39 AM	#9 (permalink)
sandsmuseum Exige enthusiast... Join Date: Aug 2003 Location: San Francisco Bay Area Posts: 759 Images: 33	miniature bungee cords work better... This has happened several times to me. I had the light replaced under warranty twice before I decided to do the fix myself. My first fix is shown here: http://www.sandsmuseum.com/cars/elis...catorlens.html Later I just drilled a small hole in the left over tab and hooked one of the small bungee cords into the hole. Then feed the other end into the hole and hook any place handy. Now the lens can be pulled out when needed, just by lifting the front of the lens... Lotus liked my fix so much they decided to implement something similar in the new front end. They upgraded my design to use an O ring instead of a bungee cord. (I fibbed about Lotus liking my design, but not about Lotus upgrading the design to use an O ring. Can anyone verify this on a new rear bumpered car?) Michael Edited to add new Lotus design comment Attached Images __________________ www.sandsmuseum.com antique coin op repair mod for the Library on EliseTalk

07-11-2007, 06:47 AM	#10 (permalink)
perryeyges XPRMTL Join Date: May 2004 Location: Berzerkley Posts: 3,010	JMA, it's funny that your avatar shows a car in the corkscrew. I have heard of more than one 996 Porsche that has had a headlight pop out under the torsional flex exerted on the chassis in the corkscrew. When a 996 headlamp assembly pops out it will cost you up to $1,600 to replace the scraped up unit. OUCH! __________________ 05 Elise Spyder II, Chrome Orange, 1,480 lbs(?) and dropping. Pure driving bliss!

07-11-2007, 07:26 AM	#11 (permalink)
Surferjer No more cone damage! Join Date: Dec 2003 Location: Phoenixville, PA Posts: 8,827	Mine popped out on a cone direct hit at 60 MPH. I was able to simply pop it back in and haven't had an issue since then. Here's a pic. My daughter is saying "Ummmm, Dad?" nd I'm replying "Shutup Jess, I know!" I completed the run and fixed the light in time for the next run. Attached Images __________________ Jer-2005 Elise (retired from autox) 1993 MR2 autox car 2002 Ford Excursion DIESEL 4 X 4 1993 Miata (future LeMons car) 1987 Toyota Corolla FX16 Lemons car (rolled-being rebuilt-maybe) 1984 Chevy Citation Lemons car (almost ready)

07-11-2007, 07:47 AM	#12 (permalink)
LARRY It's a Lotus Join Date: Oct 2005 Location: Beverly Hills, Ca. Posts: 15,067	A small amount of automotive glue/goop is holding mine back in until I next see the dealer. A little on each side of the turn signal holder, and hold it on there for a few minutes. Works. Stays put. __________________ 2005 Saffron Yellow Elise. Lotus Service and Paint by Julio and Stephan at Mulholland Motorsports near Beverly Hills at 310-360-0948. "We know they're magical and worth every minute we spend on them. The whole Lotus owners' world is like a secret handshake among people who understand that." (R&T)

07-11-2007, 09:39 AM	#13 (permalink)
shay2nak GGM ENFORCER Join Date: Dec 2003 Location: Land of da 1000 Oaks, CA Posts: 14,344	all they got to do is put a screw up there where the access hole is. Unscrew and remove...how easy is that? __________________ save ~10 lbs gain 1 hp EQ: Y=(190X) / (1984-X) where Y is (HP) and X is (lbs) '07 EXIGE S * MY CAR ** VIDEOS! '08 ACURA TSX 6-speed http://www.makeNYNYagain.com

08-03-2007, 09:58 PM	#15 (permalink)
AttAkker Registered User Join Date: Dec 2005 Location: SoCal Posts: 345	A truly solid clean - Fix Both have mine have popped out in just 2 months. I messed with a few ideas, but finally came up with this fix. Here it is Attached Images __________________ AttAkker ------------------------------------------- 2004 Noble M12 GTO3R, 2006 Maserati Gransport, 1990 Ferrari 348 TS, 2006 Porsche Cayenne Turbo S

08-04-2007, 05:46 AM	#17 (permalink)
RoadDad Ima Dork Join Date: Dec 2006 Location: La La Land Posts: 5,173	how about a very small bunge cord instead of the spring to save weight? my '07 elise has a small retaining bunge cord traveling cross ways that the clip hooks under before clipping under the clam. Don't know if this is a fix by Lotus or if the earlier models also have this. It holds very tightly and makes it even a bit harder to get the turn signal out. __________________ Almost back to normal 泣き面に蜂俺は道のお父様だ

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08-04-2007, 02:09 PM	#18 (permalink)
AttAkker Registered User Join Date: Dec 2005 Location: SoCal Posts: 345	The spring weighs practically nothing and it's cleaner than just a bungee IMHO. Also they tend to stretch over time wheras the spring should have long life. Whatever works best for everyone'd taste. I was just offering up what I came up with. __________________ AttAkker ------------------------------------------- 2004 Noble M12 GTO3R, 2006 Maserati Gransport, 1990 Ferrari 348 TS, 2006 Porsche Cayenne Turbo S

08-05-2007, 09:12 AM	#19 (permalink)
JMA Love that Lotus Join Date: Feb 2007 Location: Tujunga, CA Posts: 207	Thanks for all the advice. I took the car back to the dealer and he replaced just the surrounds. Only have about 50 miles on it since then (been out of town), but time will tell. The springs/bungee cords sound good, so may try that if they come out again. Now I carry some black electrical tape and scissors, just in case. Starting to build up a supply of repair items like I do with my 1954 MG TF. Lots of roadside restorations there, too. Thanks again. __________________ Jack-'06 Elise BRG