Rebuilding Elan +2 rear suspension struts and replacing wheel bearings is usually a routine operation at Lotus Marques.
However, nothing could prepare us for what had been sent by an inter-state customer.
It is unfortunate that the numerous parts need to rectify all the subsequent problems were not the fault of our good customer.
As this job progressed it became clear that substandard components had been previously installed in the UK.
Rear driveshaft damaged by wheel bearing 
Damaged keyway in rear hub
Above left photograph - The unwanted grove in the outboard drive-shaft has been caused by the bearing no longer being an interference fit on the shaft.
Above right photograph - The internal key-way has been damaged by movement between the drive-shaft and hub.
Badly treated rear hub 
Original hub has poor taper contact
Lotus elan +2, new rear hub 
Home made, two piece driveshaft
Above left photograph - The key-way in the brand new hub has been machined incorrectly so the locking taper would not engage fully.
To rectify this problem, the semi-circular key-way had to be carefully re-machined.
Above left photograph - This "home-grown" drive-shaft was dimensionally incorrect the locking taper would not engage when the locking nut was torqued.
No step from hub to shaft shoulder 
Step between new hub and shaft shoulder
Making sure the hub fits on the drive-shaft is essential in preventing movement between these components.
An initial check should be carried out with the dowel installed in the key-way and then with no dowel in the key-way.
This quick check can be carried out by measuring the step from the hub to the drive-shaft shoulder.
If there is any variance, then the key-way way detail is incorrect and should be examined closely.
To ensure the hub to drive-shaft mesh is correct, Engineers Blue should be applied to check the integrity of tapered contact surfaces.
Checking taper engagement 
Final assembly
On final assembly, left-hand threaded hub should be installed on the left-hand-side of the vehicle.
And the right-hand threaded hub should be installed on the right-hand-side of the vehicle.
With the hubs installed on the outboard drive-shaft, the 5/8"UNF nyloc retaining nut should be torqued to 100 - 110 lbs/ft.
Copyright © 2014 Lotus Marques
However, nothing could prepare us for what had been sent by an inter-state customer.
It is unfortunate that the numerous parts need to rectify all the subsequent problems were not the fault of our good customer.
As this job progressed it became clear that substandard components had been previously installed in the UK.
Rear driveshaft damaged by wheel bearing 
Damaged keyway in rear hubAbove left photograph - The unwanted grove in the outboard drive-shaft has been caused by the bearing no longer being an interference fit on the shaft.
Above right photograph - The internal key-way has been damaged by movement between the drive-shaft and hub.
Badly treated rear hub 
Original hub has poor taper contact
Lotus elan +2, new rear hub 
Home made, two piece driveshaftAbove left photograph - The key-way in the brand new hub has been machined incorrectly so the locking taper would not engage fully.
To rectify this problem, the semi-circular key-way had to be carefully re-machined.
Above left photograph - This "home-grown" drive-shaft was dimensionally incorrect the locking taper would not engage when the locking nut was torqued.
No step from hub to shaft shoulder 
Step between new hub and shaft shoulderMaking sure the hub fits on the drive-shaft is essential in preventing movement between these components.
An initial check should be carried out with the dowel installed in the key-way and then with no dowel in the key-way.
This quick check can be carried out by measuring the step from the hub to the drive-shaft shoulder.
If there is any variance, then the key-way way detail is incorrect and should be examined closely.
To ensure the hub to drive-shaft mesh is correct, Engineers Blue should be applied to check the integrity of tapered contact surfaces.
Checking taper engagement 
Final assemblyOn final assembly, left-hand threaded hub should be installed on the left-hand-side of the vehicle.
And the right-hand threaded hub should be installed on the right-hand-side of the vehicle.
With the hubs installed on the outboard drive-shaft, the 5/8"UNF nyloc retaining nut should be torqued to 100 - 110 lbs/ft.
Copyright © 2014 Lotus Marques
