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Lotus Evora. Instruction - part 39

Lotus Service Notes

Section FL

FL.1 - GENERaL DESCRIPTION

The 6-speed transmission assembly is an 'end on' type, positioned at the left hand side of the powertrain,

and is supplied by the Toyota Motor Corporation under the designation Ea60. The unit is fully described on

CD Lotus part number T000T1507 (Toyota ref. SC02J1Ea).

Insert the disc into a personal computer, and it will automatically open up to an avensis menu page. Se-

lect:

New Car Features Supplement.

2005.04 Update.

New Features.

Instruction Transaxle.

Ea60 and Ea61 Instruction Transaxle (disregard shift lever description).

Note that the Ea60 transmission is not used by Toyota in combination with the 2GR-FE V6 engine. For

the Evora application, a fully machined, cast alloy adaptor plate is interposed between the engine and transmis-

sion, the clutch housing of which is machined to accept the mounting of the starter motor via a further adaptor

block.

The transmission serial number is engraved on the top surface of the transmission front case, alongside

the jointline with the rear case. Typical example: a7H05232

FL.2 - GEaRCHaNGE MECHaNISM

Two control cables run along the centre of the cabin and beneath the fuel tank and power unit, and transmit

the movement of the gearchange lever to the transmission selector housing.

The gear lever is spring biased towards

the 3rd/4th gear plane, by springs at both the

lever end, and within the transmission. The

lever must be moved against light spring pres-

sure to the left before selecting first or second

gear, or against similar pressure to the right

before selecting 5th or 6th speed.

Engaging Reverse Gear:

With the vehicle at a

complete stand-

still, pause for a moment with the clutch pedal

fully depressed before moving the lever to the

left, raising the lift collar beneath the knob, and

then further to the left over a spring detent

before finally pushing forwards to engage the

gear.

a two cable mechanism is used to connect the gearchange lever with the transmission, one cable ('shift')

to transmit the fore/aft movement of the lever, and a second ('crossgate') cable for the sideways movement.

The gearchange lever is pivotted at its base and operates the shift cable directly via a ball joint half way up the

lever. The base of the lever has an extended ball pin on the right hand side which engages with a crossgate

bellcrank lever, the other leg of which operates the crossgate cable.

an inhibit mechanism prevents the gear lever being moved into the reverse gear plane unless a collar

beneath the gear knob is lifted. This action raises a boss at the base of the lever above a curved inhibitor block,

allowing the lever full leftward movement.

The front end of both inner cables are equipped with socket joints which engage with ball pins fitted on

the gearchange mechanism. The outer cables are retained by a forked plastic block bolted into the gearlever/

handbrake mounting frame.

at the transmission end, each outer cable is located in an abutment bracket by a spring 'C' clip, with the

eye of the inner cable retained in its selector lever by a washer and 'R' pin. The shift cable connects directly to a

lever on the cross-shaft to cause its rotation, the action smoothed by an extension to the lever carrying a damper

mass. The crossgate cable connects to a bellcrank lever which imparts an axial motion to the cross-shaft.

LIFT

COLLAR

6-SPEED CHANGE PATTERN

ohs15a

Lotus Service Notes

Section FL

Gearchange Cable Adjustment

In order to ensure smooth selection of 1st/2nd gears, it is important to set the crossgate cable adjustment

in relation to the fixed position reverse inhibitor block.

Push the lever to the left to abut against the reverse inhibitor block, and check selection of 1st and 2nd

gears. There should be no obstruction to fore/aft movement of the lever.

If fore/aft baulking occurs, determine whether the 1st/2nd unobstructed plane is too far left or right of where

it needs to be (i.e. adjacent to the inhibitor block). For example, if smooth operation can be achieved only

when the lever is moved slightly away from the inhibitor, the plane needs to be moved leftwards.

Remove the gear lever shroud. Release the ball pin from the crossgate bellcrank lever, loosen the locknut

and to move the plane to the left, screw the ball joint socket further onto the cable by one turn clockwise.To

move the plane to the right, turn counter-clockwise before re-attaching to the bellcrank and testing. Once

a setting is found which allows smooth fore/aft lever movement whilst abuting against the inhibitor block,

secure the ball joint socket with the locknut. Note that adjustment is available also at the transmission

end of the cable.

Raise the reverse inhibit gear lever collar and check that reverse gear can be engaged.

Refit the shroud and check that all gears can be selected without the lever fouling the shroud aperture. If

necessary, fit shim washers behind the reverse inhibitor block to move the lever away from the LH side of

the aperture and re-adjust the crossgate cable as necessary.

If other adjustments have been made, check the alignment of the 3rd/4th lever plane. From the spring

loaded neutral position, it should be possible to smoothly engage 3rd and 4th gears without moving the

lever across the gate. If necessary, the ends of the centralising hairpin spring may be reprofiled to reset

the neutral plane.

Crossgate cable Shift cable to

to transmission transmission

Lift collar

Abutment bracket

on transmission

Shift cable

Crossgate cable

pl4705eg

Gear lever/parking brake mounting bracket

Lotus Service Notes

Section FL

Gearchange Cable Replacement

For access to the gear cables, the gear lever shroud and parking brake lever trim panel must be removed,

and the gear lever/parking brake support channel released from the chassis tub floor:

Remove centre console: See sub-section VE.5.

Remove the engine bay undertray.

Release cables, front: Disconnect the front end of each cable by prising off the end socket from its gear

lever or crossgate lever ball pin. Release the outer cable abutment clamp from the mounting frame. also

release the parking brake cable from the lever and disconnect the parking brake tell tale switch.

Mounting frame: Release the gear lever mounting frame from the support channel, and withdraw.

Release the support channel: Remove the 12 screws securing the support channel to the floor of the

chassis tub to allow the gear cables to be released from the 'P' clips inside the support channel.

Release cables, rear: Release the cables from the transmission levers and abutment bracket by removing

the 'R' clips and 'C' clips respectively. Release all cable retaining clips and ties, and remove the cables

from the car.

Refit the cables in reverse order to removal, and check adjustment as detailed above.

Hairpin spring

Bellcrank lever

Grease these areas

Pivot stud

Fixing to floor channel

Lotus Service Notes

Section FL

FL.3 - LUBRICaTION

The engine and transmission should be inspected for evidence of oil leaks at every service, and the trans-

mission oil renewed at intervals specified in the Maintenance Schedule.

The transmission should be drained after a run when the oil is warm, flows more readily, and the impurities

are still held in suspension. a hex. head drain plug is provided in the bottom of the transmission crownwheel

housing. after allowing a sufficient drain period, thoroughly clean the drain plug before applying PTFE tape

around the thread, fitting a new sealing washer and tightening to 39 Nm.

a level/filler plug is located in the left hand side of the transmission case. With the vehicle at normal ride

attitude, the oil level should be within 5mm of this filler plug hole. For oil specification refer to Section OK. after

refilling, re-check the oil level at normal running temperature after a run. Finally use a new sealing washer and

tighten to 39 Nm.

FL.4 - DRIVE SHaFTS

Each of the two driveshaft assemblies comprises a steel shaft with a constant velocity (CV) joint at each

end, and is used to transmit the drive from each differential output gear to the rear wheel hub. The longer right

hand driveshaft assembly features an outrigger bearing bolted to the right hand side of the cylinder block, with

a shaft extending from the inboard CV joint into the transmission housing.

The inboard joints are of a plunging tripod design to accommodate driveshaft length variation with sus-

pension travel, whereas the outboard joints are high efficiency 6-ball fixed length type. Replacement outboard

joints include the main driveshaft, outboard C.V. joint and gaiter. Replacement inboard joints include the inner

C.V. joint and gaiter kit, with the extended stub shaft of the RH joint also including the support bearing and

mounting bracket.

The joints themselves are packed with grease on initial assembly, and are maintenance free. It is however

vitally important that the protective gaiters are carefully inspected at service intervals, to check for splits, tears

or punctures, since the joint will deteriorate very quickly once contaminated with dirt or water. Damaged gaiters

should be renewed immediately, once the servicibility of the joint has been established.

CAUTION: The outboard C.V. joint gaiter can suffer 'pinch' damage if the joint is subjected to extreme articula-

tion off the car, or during driveshaft removal/refitment.

LH Driveshaft Assembly

RH Driveshaft Assembly

Outboard joint Inboard plunging joint

f140

Extension shaft Inboard plunging joint Outboard joint

f141

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