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A recommendation...

Now I'm going to make sure to bring my car into the dealer to get it checked out ASAP. I hope the syncros aren't going but it seems to fit the symptoms and the mileage people started having problems at, 2005 with 8700 miles on it.
Before you go in to the dealer, I'd say do a really good search on this forum and find all the examples of this. Be creative with search terms and make sure you find all you can. Since not all Elise owners are on ET, this will only be a fraction of the real total, but should be good evidence to support your case.

Good luck - and be sure to let us know how you fare!...:popcorn:
 

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I had the 3rd to 2nd grind and had to get a new trans at 4500mi., Lotus covered it,
The new one is much better but the cold 3rd gear grind is now there,
the old one only had an issue with 3 to 2 downshift.

I make sure to warm up the car before using 3rd, otherwise, grrrrrrrind.
 

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If you start to develop a grind when upshifting or downshifting, I strongly recommend trying to get it covered under warranty if possible. The grinding issue will only get worse. While you may think you can live with it as it is at present, by the time your warranty is up, it may be more than you can live with.

I talked to 2 dealers about the cost of the trans. I got quotes of $6800.00 and $6200.00. Add a days labor to that also.
 

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Well, I hate to resurrect this thread, but it looks like my 2nd gear synchro has failed too. 12,200 miles, 1 year, 3 practice auto-x's only (no competition). It started about two weeks ago occasionally, now it grinds every time I downshift into second where the revs would be > ~3,000 in second. If I double-clutch, it's silent. Dealer has been notified, but I haven't brought it in for inspection yet. More to follow...
 

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Brought the car in yesterday to have the synchro checked... Symbolic verified the failure, and Lotus has approved a replacement under warranty. :clap:

Now I just have to wait for the transmission to cross the pond... :sad:
 

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Add another one to the list. '07 Exige. Just brought it in for the 15,000 service. Had it back two days and have grinding up from 2nd to 3rd and down from 3rd into 2nd. Weather has turned pretty cold and engine never really got fully warmed up. Hopeing a spirited, longer drive tomorrow will lessen the problem but clearly a problem exists. I've spent an hour researching this issue on LT and the grinding is almost always up into 3rd and (more prevalent) down into 2nd. Can there be any doubt that there is a weakness in those syncros?
 

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Just an interesting observation...

With my original transmission, whenever it was even slightly chilly outside (SoCal definition: < 70 degrees F) I'd have to be slow and smooth with my 2-3 upshifts, or it would grind slightly going into third. As soon as the car warmed up, no problem.

With my replacement transmission, I've never had that slight grind going from 2-3, even when it's "chilly" outside and the car is cold.

I wonder if there's some significance to this... are transmissions that "grind" on the 2-3 upshift while cold more likely to fail long term? Or has Lotus changed components in the newer transmission to address these problems?

Maybe time will tell...
 

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I get a slight "grind" when I shift from 2nd -> 3rd when the car is cold, it's not an audible grind, just a slight feel of grind.

14,500miles, hopefully the transmission will last a while. :eek:
 

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Now that it's warmed up (by only about 15 degree) the grind is gone! (50 degrees- grind, 65 degrees- no grind). If we're getting this in Cali, surely our east coast bretheren are experiencing this phenomenon.
 

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Help.

Plus one for the 2nd gear syncro issue. '06 with just over 4,000 miles, warranty expires in March.

Plus one for factory failing to pay for.

"After Lotus warranty review,was informed that issue is due to excessive track driving and is not warrantable. Also was informed that due to engine data,vehicle drivetrain warranty has been flagged as voided"

Car has only been tracked a few times, however it has been autocrossed more.

They seem to be basing this on the 60+ standing starts.

Did I mention this was my 2nd new Elise, I don't think their will be a third Lotus as tempting as the Exige S is.

I forgot to mention I also paid out over $1,000 to repair/replace motor mounts that came loose that Lotus denied a claim on.
 

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Help.

Plus one for the 2nd gear syncro issue. '06 with just over 4,000 miles, warranty expirers in March.

Plus one for factory failing to pay for.

"After Lotus warranty review,was informed that issue is due to excessive track driving and is not warrantable. Also was informed that due to engine data,vehicle drivetrain warranty has been flagged as voided"

Car has only been tracked a few times, however it has been autocrossed more.

They seem to be basing this on the 60+ standing starts.

Did I mention this was my 2nd new Elise, I don't think their will be a third as tempting as the Exige S is.
I wonder what the ECU flags as a "standing start"? Does anyone know the actual criteria (delta RPM/ delta T?, RPM vs. MPH?)? I've done a few autocross days, and I don't think I had any standing starts.
 

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Help.

Plus one for the 2nd gear syncro issue. '06 with just over 4,000 miles, warranty expires in March.

Plus one for factory failing to pay for.

"After Lotus warranty review,was informed that issue is due to excessive track driving and is not warrantable. Also was informed that due to engine data,vehicle drivetrain warranty has been flagged as voided"

They seem to be basing this on the 60+ standing starts.
That seems like a logical bet.
 

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I'd call it more of an easy out. If were not for so many others having the same issue I'd consider swallowing the pill as I did with the motor mounts but this just isn't right.
 

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I wonder what the ECU flags as a "standing start"? Does anyone know the actual criteria (delta RPM/ delta T?, RPM vs. MPH?)? I've done a few autocross days, and I don't think I had any standing starts.
I have heard that anything over 3k rpms is considered a standing start..

I launch my other cars all the time and I do not have any issues with them.. Only regular clutch replacements..
 

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I'd call it more of an easy out. If were not for so many others having the same issue I'd consider swallowing the pill as I did with the motor mounts but this just isn't right.
Yep... I don't see how a typical standing start (select first, rev engine, drop clutch) would damage the second gear synchro... but I'm not a transmission specialist. I could see where that would stress the motor mounts though. My guess (in least in my case) is it had to do more with all the play in the shift linkage and motor mounts, which made it very easy to think you were in gear when you really weren't. Since reinforcing the shifter I've had a huge improvement in shifter accuracy, and I assume it would be even better with stiffer motor mounts. That seems more like a design defect IMHO...
 

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I have heard that anything over 3k rpms is considered a standing start..

I launch my other cars all the time and I do not have any issues with them.. Only regular clutch replacements..
Yes, but I assume if you revved to 3K rpm and let the clutch out slowly that it wouldn't be a standing start. If I were to guess, I'd bet it has something to do with the change in RPM per unit time when the car is standing still (it's already being measured to determine misfire). A very rapid change in RPM (downward, of course) while standing still would indicate a clutch drop...
 

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Help.

Plus one for the 2nd gear syncro issue. '06 with just over 4,000 miles, warranty expires in March.

Plus one for factory failing to pay for.

"After Lotus warranty review,was informed that issue is due to excessive track driving and is not warrantable. Also was informed that due to engine data,vehicle drivetrain warranty has been flagged as voided"

Car has only been tracked a few times, however it has been autocrossed more.

They seem to be basing this on the 60+ standing starts.

Did I mention this was my 2nd new Elise, I don't think their will be a third Lotus as tempting as the Exige S is.

I forgot to mention I also paid out over $1,000 to repair/replace motor mounts that came loose that Lotus denied a claim on.
Sorry to hear that. Welcome to the club!

FWIW, I joined the elite with no standing starts. Go figure! :rolleyes:
 

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Time for class action?

I've been lucky in that I have had two gearbox replacements covered under warranty before my '06 hit 10k miles. Fortunately I didn't have any standing starts, which seems to be the standard bogus pretext for denying a claim.

To my mind this looks like a design defect - there are so many instances of this same failure that it's hard to think otherwise. But if we let them pick us off one by one most of the time the claim will be denied. Surely there must be a legal eagle on this board that can organize a structured defense?
 

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My 2nd Elise has had no synchro issues, which is good because I'm now off warranty. HEY LOTUS-my standing start count is well over 100 due to SCCA Pro Solos, and guess what-no synchro issues! I also have high revs in the 8800 range, and not from mis-shifts, and guess what-no synchro issues!

Tell me again how the synchromesh issue is caused by this so-called "abuse"?
 
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