Author Topic: Another 46 to 47 project!  (Read 21957 times)

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Offline GavinT

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Re: Another 46 to 47 project!
« Reply #180 on: Saturday,November 26, 2022, 07:06:08 PM »
Roger that, Kendo, but the pic in Reply #161 is of Serge's car.
Anyway, it looks like Dreams has straightened me out.

Dreams, good news, indeed.
I agree if the brake pedal is now acting up, it seems time to remove the pedals for an R&R – too much stuff not happening properly there. Best to also remove the cable so you can assess that as well.
Also interesting is that in your latest pic of the abutment, the cable ferrule shows a build up of crud which would indicate it hasn't been correctly seating in the abutment for some time.

I wouldn't worry about the release bearing etc. just yet – diagnosis is a process of elimination. I suspect that'll magically come right when the pedals are fixed.

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #181 on: Saturday,November 26, 2022, 07:58:33 PM »
Turbo, tomorrow I'm definitely going to remove the pedal assembly and clean and lubricate the whole thing. Seeing how it's a nested system gunk of any kind getting in the assembly surely would really mess it up. However the system not operating happened all of a sudden and it was working without any issues before so gunk build up or rust seems to be unlikely. I'd put probably 50 miles on the car without any indication of pedal trouble whatsoever, but I guess anything is possible  :confused:

Richard the pedal did not move any better when I had the cable disconnected from the clutch arm. It still had just as much resistance and didn't cooperate. Also I should have mentioned that I tightened the crap out of the clutch cable before it would return the pedal even with the lubricant. I'm not sure what trans I have. I know that the shift pattern is different from the pattern in the early cars in regards to reverse but I'm not certain. The gearbox tag is knackered and illegible but I do have the external return spring on the arm which is intact and functioning and I also lubed heavily. It seems there are 2 access hole in the bell housing and I could tray and spray lubricant in there but I'm afraid of accidentally spraying the clutch disc so I may hold off on that for the time being.

Gavin, the clutch cable has a inner braided cable thats then coated in a black rubber lining that then also sits inside and large armored sheath that sits against the abutments. Hopefully some TLC on the pedals fixes the issues, but I'm not convinced it's just pedal trouble. Also you gents should have seen the literal rat's nest that had been created under the seat! The cavity had been made home by some creature but it had left long before I started working o the car. Y'all wouldn't believe the amount of leaves and seeds I vacuumed out! I'll give you all an update as I try and get those pedals out.

Offline TurboFource

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Re: Another 46 to 47 project!
« Reply #182 on: Sunday,November 27, 2022, 03:54:06 AM »
Check out TCST if you want to see critter debris!,,,,
The more I do the more I find I need to do....remember your ABC’s …anything but chinesium!

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #183 on: Sunday,November 27, 2022, 07:34:22 PM »
Well, Lads it seem that the pedal removal and regressing has done the trick. The brake pedal returns as expected and the clutch appears to be functioning. I do have a concern though: I'm not sure if the clutch pedal is returning to where it should be. The mechanism appears to be functioning as it ought to but I'm not sure of the clutch is engaging where it should in the pedal throw and I'm not sure if the pedal is returning to where it should. Corollary to that, how much should I have to adjust the clutch cable? Or rather how many inches of adjustment rod should I have extending aft of the clutch arm and pivot. Something tells me that the cable wasn't adjusted properly before I had any issues, but where do y'all have the cable? I know one should check the adjustment by movement of the arm, but I'm figuring a rough inches number will at least tell me if I'm way off base or not.

Oh and Turbo that is definitely some critter litter! I know it could have ben worse but I was still quite surprised to find it where I did!

Offline GavinT

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Re: Another 46 to 47 project!
« Reply #184 on: Sunday,November 27, 2022, 11:10:38 PM »
Excellent . . more good news, Dreams.
Can't help with a 'correct' cable length as my OEM cable went long ago, but whatever pedal position is comfortable for you can be adjusted at the rear threaded end while taking into account the physical 'stop prong' welded to the pedal assembly. At least, that's how it's done on my S2.

Offline jbcollier

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Re: Another 46 to 47 project!
« Reply #185 on: Monday,November 28, 2022, 07:44:54 AM »
http://www.lotus-europa.com/manuals/s2work/q/index.htm#4

Adjust as per manual and then evaluate.

Offline jbcollier

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Re: Another 46 to 47 project!
« Reply #186 on: Monday,November 28, 2022, 07:51:44 AM »
There's a wrinkle, of course.  The S1 pedal assembly doesn't have a clutch pedal stop.  So the clutch adjustment is really about adjusting the clutch pedal position: Tighten to "raise the pedal, loosen to lower.  The only limit is that it has to be fully disengaged at the bottom of its travel.

Your cable is obviously not stock  -- not unusual, I'm running a VW type 2 cable myself -- so how much thread is exposed is not necessarily indicative of anything as long as you have enough thread to make the required adjustments.

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #187 on: Monday,November 28, 2022, 08:44:12 AM »
I figured it was a matter of measuring throw and hopefully I can get around to doing that today with some daylight.

Funny thing regarding that pedal stop: a previous owner actually replaced the front of the 2 mounting bolts and lock-nuts with a tapped aluminum block to serve as both the nut and a makeshift pedal stop and it seems to work well. Hopefully soon I can do a little more troubleshooting and get the pedal feel and clutch adjustment dialed in.

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #188 on: Monday,November 28, 2022, 08:50:50 AM »
I think y'all will appreciate the pic of the car getting loaded onto the tow truck after my first Lotus breakdown!  :FUNNY:

Offline TurboFource

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Re: Another 46 to 47 project!
« Reply #189 on: Monday,November 28, 2022, 09:08:45 AM »
 :help:
The more I do the more I find I need to do....remember your ABC’s …anything but chinesium!

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #190 on: Tuesday,November 29, 2022, 06:28:17 PM »
Gentlemen, bad news... after a day of small errands and testing around the neighborhood the clutch is acting as it was before. The clutch will disengage at the floor but it won't return, and this time no amount of tightening the cable is pulling it back. I'm thinking that, given that it appears the problem is getting progressively worse as the car is driven, that it must be an issue with the release bearing or the pressure plate failing. Considering how much of the car needs to be disassembled to get the gearbox out I'm not sure when I'll be endeavoring to complete that project but we'll just have to see.

Also I still can't get the fan to work! I tested the original fan currently still in the car and it does not work. I have a new one that I confirmed works and can install it at some point soon, but just to be sure I tried hooking the new fan up to the harness to ensure that it would all work... and I got nothing. I tried both the old relay and the new 5-pin and I can't get power to the fan. I also tired bypassing the thermal switch and dash switch and I still got nothing.

Offline jbcollier

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Re: Another 46 to 47 project!
« Reply #191 on: Tuesday,November 29, 2022, 07:59:37 PM »
It sounds like the clutch may be the culprit.  Time to remove the transaxle and see.

You need to have someone who understands auto electrics look at your fan wiring.

Offline GavinT

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Re: Another 46 to 47 project!
« Reply #192 on: Tuesday,November 29, 2022, 08:38:03 PM »
Just to confirm a few things:
Does the clutch pedal still move freely, independent of anything else?
Does the clutch cable move freely, independent of anything else?
Did you R&R the cable?

Noticed the cable was not located in the front abutment in your last pic.
Is it now correctly located or has it jumped out again?
Is the cable properly located in the rear abutment?

If all this is OK, then jerry rig a breaker bar to the clutch lever to assess movement – a length of pipe slipped over would seem to be the easiest idea, but whatever works.
Your clutch lever uses an external spring, right? Detach it from the lever temporarily.

On the wiring, I'd make up a test lead with a bulb to establish validity of the wiring.

Offline DreamsOfA47

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Re: Another 46 to 47 project!
« Reply #193 on: Thursday,December 01, 2022, 08:30:27 AM »
JB, I agree with you on both counts! I'll begin to do research on what it's like to pull the gearbox from an S1 or S2 on the forums and prepare myself. Considering it'll be a big job I may as well change out all the hoses and water pump like I was planning on at the same time. I was also thinking of an RB aluminum swirl pot and that may be a good time for that too. I think the last thing I may do is check the continuity of the wires with a multi-meter just to make sure the harness doesn't have a break or bad connection somewhere.

Gavin, yes to all 3; the clutch pedal moves freely when push or pulled to the extremes of its throw, the cable moves as it should with the pedal and I did check and clean and lube the cable with some dry lube (PTFE) spray. The cable is now properly located in both abutments and the problem of the pedal not returning has reared its ugly head again, I managed to drive the car around for a couple days and the pedal got progressively worse until it stopped returning again. I have yet to stick a breaker bar on the arm and try to move it but if i'm able in the near future I'll try and make that happen.

The interesting thing is that when the pedal is depressed, the clutch is disengaged and the car is in neutral. I was able to give the car some gas and then pull slowly the clutch pedal back with my toes and the car would then roll in gear as normal. Maybe my pressure plate springs have failed? Considering the clutch is quite old I think I'll replace all the components on principle to move forward with a a clean slate. A new pressure plate, clutch disc, release bearing, cable and a freshly surfaced flywheel should cover all the bases on a clutch replacement.

Offline GavinT

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Re: Another 46 to 47 project!
« Reply #194 on: Thursday,December 01, 2022, 03:42:01 PM »
That's a bummer, Dreams.

If you can get a breaker bar on the clutch lever, you could likely 'feel' what's going on.
I'm now wondering if it's ingested a gallon of coolant from the water pump leak and gummed up the doings.

Anyway, I reckon it should be possible to drop the gearbox onto the deck without dismantling absolutely everything.