The only modification that may be necessary is, to remove the rotoflex fail-safe pins that were installed on later production vehicles.
Lotus Elan differential driveshaft The photograph above shows the late type differential driveshaft complete with fail-safe pin
These pins are approximately 10mm diameter by 38mm long and are welded to the centre of the drive flange of the differential and outboard drive shafts.
The first step is to remove the original intermediate drive shafts and rotoflex couplings.
These items should be carefully stored away, complete with the high tensile bolts and nyloc nuts.
Next, inspect the differential output drive shaft and wheel axle drive shaft for any signs of wear of damage.
Pay careful attention to the boltholes and check for ovality as this may make installation difficult.
If there are any signs of significant wear, then for safety reasons the relevant component should be replaced.
For ease of fitment, install the adapter plate at the differential output shaft and then fasten the other adapter plate at the wheel hub drive shaft. Install the adapter plates on the shafts with the 7/16 UNF studs and nyloc nuts but do not tighten.
NOTE. The longer stud adapter should be installed at the wheel hub drive shaft location.
NOTE. The shorter stud adapter should be installed at the differential drive shaft location.
When attaching the CV joints to the adapter plates, check that the 7/16 UNF studs in each plate are directly opposite or in phase with each other. This ensures the smooth action and operation of each CV joint during rotation. At this point the nyloc nuts may be tightened using a torque wrench.
NOTE. During the manufacturing process, the CV joint cap screws have been tightened to the correct torque setting of 15ft/lbs.
NOTE. The recommended torque setting for the adapter plate nyloc nuts is 45ft/lbs to 55ft/lbs. The correct tools and thin wall series socket are required for this task.
After all the fixing bolts and screws have been installed correctly, check the CV drive shaft assembly and associated components are free (and smooth) to rotate with the suspension at full droop. By grasping the drive shafts, check they are free to slide in and out the CV joints from 3mm to 10mm. If this is not possible, then please contact us immediately as there may be a problem with your suspension or chassis.
After an initial running period of approximately 500kms, check all bolts and cap screws again for tightness. The above procedure should be followed to ensure a safe and trouble free installation of your new solid drive shaft assemblies.
Routine Maintenance
It is recommended that the CV joints should be re-packed with Molybdenum based grease every 8000kms to 10,000kms.
It is also recommended that the rubber boots be periodically inspected for fractures.
Any splits or cracks will allow grit and water to enter the CV joint and coversely grease will be lost causing premature failure.
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