2007 Exige Front Clam Removal - LotusTalk - The Lotus Cars Community
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post #1 of 20 (permalink) Old 07-04-2016, 04:14 PM Thread Starter
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Question 2007 Exige Front Clam Removal

Hi all, hoping to find some help/advice. I'm currently removing the front clam on a 2007 Exige and I've followed the numerous write ups and have removed all the fixings on the car... but is seems that the clam is still attached in the middle/front.

In a few write ups they talk about a lip on the clam that connects to a lip on the crash structure, but I'm not seeing this. Also this clam has the bonded wire mesh, which means I'm unable to get my hands under the middle spline of the clam to try and lift it up.

By chance has anyone else run into this issue and any tips of how to get the clam off?

This is the first time taking the clam off for me (replacing the radiator) and I'd like not to crack it or damage the windshield... or anything else that will cost too much to repair. Thanks.
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post #2 of 20 (permalink) Old 07-04-2016, 05:04 PM
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So does that mean you can't get to the two bolts bear the windshield under the spline? You'll need to find a way to remove the mesh or weasel a wrench in there


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post #3 of 20 (permalink) Old 07-04-2016, 05:40 PM
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If you're taking of the clam the headlights need to come out

"Give a man a match, and he'll be warm for a minute, but set him on fire, and he'll be warm for the rest of his life."
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post #4 of 20 (permalink) Old 07-04-2016, 05:50 PM Thread Starter
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So I got the bolts that hold the spline by the windshield wiper. On this car there's actually a bracket and bolts and nuts that's much easier than the how to's. I can move the spline freely from the windshield side, it feels like it's still secured in front of the radiator, but I can't see or find anything.

Also I've done the head lights, they are the 07+ type that there's 3 18mm nuts and one 8mm nut to remove them. I removed the 5mm hex head from each, unplugged the headlight wires, and the clam moves freely on both sides. Kind of at a loss at this point, but thanks for the double checks.
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post #5 of 20 (permalink) Old 07-04-2016, 07:47 PM
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why are the headlights in if not bolted? You need to have them out anyway, they weigh enough and provide a good hand hold

undertray off?

door aperture bolts
wheel arch liners

several harness clips
oil line clips


just did it and don't recall any big issue

watch for the antenna
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post #6 of 20 (permalink) Old 07-04-2016, 10:09 PM
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If its loose everywhere but still flexing/stuck below the rad, take a look at this.

https://www.lotustalk.com/forums/f101/stuck-clam-358433/

07 Exige Phantom Black
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post #7 of 20 (permalink) Old 07-06-2016, 06:38 AM Thread Starter
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Quote:
Originally Posted by Krule View Post
If its loose everywhere but still flexing/stuck below the rad, take a look at this.

https://www.lotustalk.com/forums/f101/stuck-clam-358433/
Thanks for the reference about the possible stuck foam. I tried to get a better view by sticking my phone in from the windshield side and tacking a picture, but all I could see is a bunch of wires.

I'll be picking up a borescope to try and get a better view before I start sawing away with a hacksaw blade.
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post #8 of 20 (permalink) Old 07-06-2016, 07:27 AM
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better pics of all the relevant areas would be more helpful to see if anyone can tell if you forgot something

someone replaced the fans, so it must come off....
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post #9 of 20 (permalink) Old 07-06-2016, 03:25 PM
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Garage
Here are pics from Work shop manual
Hope it helps
I assume you have removed both head light units. to access the screws. holding the front of the clam
you may find rubber spacers under these screws don,t loose them
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post #10 of 20 (permalink) Old 07-06-2016, 07:57 PM
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Regarding the foam,
Come at it from the wheel wells, you should be able to get your hand next to the center support to see if it is stuck. I am 6'3" and i could get my hand in there....
My clam was loose everywhere and could lift from the sides, front and rear easily. it was just the center area that was stuck. I could see the clam flexing as if it was still attached on the radiator supports when i would try to lift it.

07 Exige Phantom Black
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post #11 of 20 (permalink) Old 07-06-2016, 09:55 PM
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remove headlights and i believe there should be an allen bolt there and did you get the two nuts under the middle spline? If i remember they are 10m and if you don't use a ratchet wrench you will be there for a long time with a very sore back lol

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post #12 of 20 (permalink) Old 07-09-2016, 06:38 PM Thread Starter
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Thanks everyone for all the useful tips and chiming in. I'll attach more photos so show that I did get the bolts under the headlights. I'm not 100% on how to remove the wire plug on the back of them but it looks like the clam can come off with them attached. Also I did disconnect the antenna wire by the windscreen/center spline, and the center spline fixings are removed.

Regarding the center foam, it looks like my only opportunity to try to get in there would be from the drivers side wheel well, but I tried and my hands just not going to fit between the clam and the radiator shroud. Also I don't think I'd have the reach... I did have an endoscope on order that was supposed to be in yesterday, but looks like the carrier might have gave my packages to someone else. So I had to reorder that and maybe once that is in I can get a better look at what's going on with this.
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post #13 of 20 (permalink) Old 07-10-2016, 08:53 AM
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You are going to want to completely remove the headlights, make things easier. I had difficulty removing the big connector as it slides onto a mount on the clam, it was hard for me to pinch the release and slide off...
Once the headlight is off you can see a lot more of whats going on.

07 Exige Phantom Black
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post #14 of 20 (permalink) Old 07-10-2016, 08:59 AM
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Yeah,I found I was trying to move the wrong part, a bit confusing till you figure it out
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post #15 of 20 (permalink) Old 07-10-2016, 04:18 PM Thread Starter
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Ok, so the clams off! Looks like it was the sticky foam in the center that was holding it on...

Now for the actual business of fixing all this coolant that's escaping from the car from somewhere...
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post #16 of 20 (permalink) Old 07-12-2016, 05:31 AM
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HOLD IT! This clamp tells me you still have the stock oil line fittings. Get those replaced now with the deeper barbed fittings (4 total). That's a safety recall item!
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post #17 of 20 (permalink) Old 07-14-2016, 06:27 PM Thread Starter
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Thanks for the call out! I'm guessing that I can just flat bed the car to a dealer with the clam off and they can do the oil cooler connections...?...
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post #18 of 20 (permalink) Old 07-14-2016, 07:19 PM
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Don't let the dealer do it. I've heard there's been some failures with the new fittings the dealer installs. Probably bad installation. Plus the stories of dealers doing crappy clam installation, breaking headlight clips, etc...

I'm following the details BOE posted here: Lotus Oil Line Repair ? BOE Fabrication

I just got the fittings, clamps and hose yesterday. Total was just under $175 with shipping. Now I know the dealer can't mess up my car and the fittings will be 10x better than what Lotus provides.

You've done all the hard work by removing the front clam! Now install the correct fittings and sleep good knowing the job was done right.

08 Exige S240 - Chrome Orange
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post #19 of 20 (permalink) Old 08-02-2016, 02:47 PM
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I'm about to under take this to remedy some of the AC issues. Thanks for writing back with the results of your findings. Often people never bother to report what the solution to their problem was once fixed.
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post #20 of 20 (permalink) Old 04-30-2018, 03:38 PM Thread Starter
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Here is a quick update regarding the tape holding on the front clam:

I didn't use any tools to remove the sticky tape.

Basically, I removed all the fasteners, so the only thing holding the clam on was the tape (which I didn't know at the time).

I ordered a small bore scope and validated that it was just tape holding on the center of the clam.

After I knew that, I worked the clam, just a little bit at a time back and forth, pulling up gently. Eventually the tape tore, with one part staying on the clam, and the other part staying on the frame support.

That's pretty much it, I just was careful not to try to really pull the thing off cause I didn't want to crack the clam.

I'm not sure if a tool would, but I think something thin and flat could help pry one side off. I would aim for the side of the tape that's attached to the frame and not the clam.. hope that helps.
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