Pedal box wear problems
Pedal box wear related problems observed today could never have been foreseen by the Lotus Factory.
With continual use and the passage of time, there are significant wear patterns on the pedal assemblies of both the Lotus Elan and Elan +2.
What is a surprise, are the problems and consequences caused by the cumulative free-play in critical moving components.
Inherent design problems
Both vehicles have pedal assemblies that have restricted access and no provision for lubrication.
This usually results in the pivot spindle, pedals, clevis yoke, clevis pin and push-rods not being lubricated until such time the vehicle is restored.
Occasionally the clevis pin, yoke and push-rod may receive some attention if the master cylinder is overhauled or replaced.
Identifying and understanding wear characteristics
Examining the pivot spindle and throttle pedal reveals there is little or no wear on these components.
Whilst the throttle pedal maybe the most frequently operated, its has the lightest load which is the carburettor butterfly valve return springs.
The brake pedal can experience the heaviest loads when subjected to extreme braking situations.
However, it is generally understood the clutch pedal maybe used more frequently than the brake when shifting up and down gears in the Ford 2000E four speed gearbox.
Common brake and clutch system modifications
Installing a heavy duty clutch results in an increase in pressure required to operate the clutch pedal.
Installing an incorrect 3/4" bore slave cylinder instead of the standard 7/8" bore slave cylinder also results in a heavy clutch pedal operation.
There is an ill-founded recommendation to remove the standard Girling brake booster and to change the brake master bore size to obtain "a better brake pedal feel".
This often results in brake master cylinders being replaced without due consideration given to an increase in wear when changing bore diameter .
The remote brake booster significantly reduces brake pedal effort and is a safety critical component as it reduces stopping distances.
Removing the brake booster is an inappropriate idea as it will extend the vehicle braking distance and has the potential to invalidate any insurance claim in the event of an accident.
Why would anyone want to disadvantage themselves whilst driving in traffic when modern vehicles are equipped with stepped bore brake master cylinders that result in shorter breaking distances?
The removal of the brake booster will the increase in brake pedal force, accelerate wear on the pivot spindle, pedal, clevis yoke, clevis pin and push-rod plus results in excessive flexing of the fibreglass firewall.
Diagnosing and rectifying excessive pedal free-play requires examination of all the moving parts and understanding whats causes the related wear - see part 2
Copyright © 2018 Lotus Marques
Pedal box wear related problems observed today could never have been foreseen by the Lotus Factory.
With continual use and the passage of time, there are significant wear patterns on the pedal assemblies of both the Lotus Elan and Elan +2.
What is a surprise, are the problems and consequences caused by the cumulative free-play in critical moving components.
Inherent design problems
Both vehicles have pedal assemblies that have restricted access and no provision for lubrication.
This usually results in the pivot spindle, pedals, clevis yoke, clevis pin and push-rods not being lubricated until such time the vehicle is restored.
Occasionally the clevis pin, yoke and push-rod may receive some attention if the master cylinder is overhauled or replaced.
Identifying and understanding wear characteristics
Examining the pivot spindle and throttle pedal reveals there is little or no wear on these components.
Whilst the throttle pedal maybe the most frequently operated, its has the lightest load which is the carburettor butterfly valve return springs.
The brake pedal can experience the heaviest loads when subjected to extreme braking situations.
However, it is generally understood the clutch pedal maybe used more frequently than the brake when shifting up and down gears in the Ford 2000E four speed gearbox.
Common brake and clutch system modifications
Installing a heavy duty clutch results in an increase in pressure required to operate the clutch pedal.
Installing an incorrect 3/4" bore slave cylinder instead of the standard 7/8" bore slave cylinder also results in a heavy clutch pedal operation.
There is an ill-founded recommendation to remove the standard Girling brake booster and to change the brake master bore size to obtain "a better brake pedal feel".
This often results in brake master cylinders being replaced without due consideration given to an increase in wear when changing bore diameter .
The remote brake booster significantly reduces brake pedal effort and is a safety critical component as it reduces stopping distances.
Removing the brake booster is an inappropriate idea as it will extend the vehicle braking distance and has the potential to invalidate any insurance claim in the event of an accident.
Why would anyone want to disadvantage themselves whilst driving in traffic when modern vehicles are equipped with stepped bore brake master cylinders that result in shorter breaking distances?
The removal of the brake booster will the increase in brake pedal force, accelerate wear on the pivot spindle, pedal, clevis yoke, clevis pin and push-rod plus results in excessive flexing of the fibreglass firewall.
Diagnosing and rectifying excessive pedal free-play requires examination of all the moving parts and understanding whats causes the related wear - see part 2
Copyright © 2018 Lotus Marques
