Lotus Elise / Lotus Exige. Manual - part 57

   Lotus Service Notes

                Section JJ

Page 11

-

Unscrew the gear lever knob.

-

Release the fixing screw at either side of the gear lever shroud base.

-

Remove the single screw retaining the rear bulkhead centre pocket, and then the two screws securing the
rear shroud.  Disconnect the auxiliary power socket.

-

Lift the centre trim panel, label and disconnect the CDL switch and (if fitted) hazard switch, and release
the gear lever gaiter.

Note that the parking brake/gearchange lever mounting bracket is not drive handed, but is offset, via

alternative fixing holes in the chassis, towards the passenger side.  The ratchet pawl operates a micro switch
to light the 'brakes' tell tale lamp in the instrument panel whenever the ignition is switched on and the parking
brake is applied.  The short front cable is connected to the lever assembly by a clevis pin with spring retaining
clip.  When carrying out any work in this area, take care not to damage or misroute the electrical main harness.

JJ.7 - BRAKE DISCS

All four wheel brakes use a brake disc which is sandwiched between the wheel and its hub flange, being

centralised by the hub spigot, and transmitting torque via the clamping force of the road wheel bolts.  A
countersunk screw is used to retain the discs for convenience when servicing.

The same disc is used at each corner of the car, and features cast iron construction with internal curved

vane cooling and cross-drilling.  The opposite direction of rotation of the curved vanes on each side of the car
does not significantly affect the cooling performance of the disc.  The condition of the brake disc friction
surface is a major factor in brake performance and feel, with a good surface quality and minimal run-out and
thickness variation being required.  After an extended lay up, some surface corrosion may develop on the discs
which will cause a degradation in braking quality until the surfaces are cleaned up by normal brake action.
Excessive run-out or thickness variation as a result of overheating or extended wear, may cause brake judder
and/or extended pedal travel due to pad 'knock off'.  Scoring and ridging of the braking surfaces will be exac-
erbated by operation in dusty or unmetalled road environments, and will reduce braking performance.

No skimming or re-surfacing of the brake discs is recommended.  If the disc becomes badly scored, or is

out of specification in any way, it should be renewed.  NOTE: Ensure that there is no discernible free play in the
wheel bearings before attempting to measure  brake disc run-out.  If disc run-out exceeds the service maximum,
check the hub run-out before replacing the disc.
Brake disc thickness:

New

26.0 mm (1.02 in)

Service  minimum

24.0 mm (0.98 in)

Runout:

New maximum

0.03 mm (0.001 in)

Service maximum

0.10 mm (0.004 in)

Hub:

Disc mounting face run-out max.

0.04 mm (0.0015 in)

Front Disc Replacement
1.

Remove the road wheel.

2.

Remove the two bolts securing the brake calliper to the hub carrier, and withdraw the calliper from the
disc. Secure clear without straining the flexible hose.

3.

Remove the single countersunk screw, and withdraw the disc from the hub.

4.

Before re-fitting a disc, ensure that the mating face between disc and hub is scrupulously clean.  Mount
the disc onto the hub and align the wheel bolt holes.

5.

Apply Permabond A130 (Blue - A912E7033) to the threads of the calliper fixing bolts.  Fit the calliper over
the disc and secure to the hub carrier with the two bolts.  Tighten to 45 Nm (33 lbf.ft).

6.

Refit the road wheel and operate the brakes before driving the car to set the brake pad position.

Rear Disc Replacement

Replacement of the rear discs is similar to that for the front discs, except that if the brake pads are

removed, it is not necessary to remove the brake calliper to enable the disc to be withdrawn from the hub.

 

   Lotus Service Notes                                  Section JJ

Page 12

JJ.8 - BRAKE CALLIPERS

The front brake callipers are manufactured by A.P. Racing, and are to be dismantled or overhauled only

by their factory at Wheeler Road, Seven Stars Industrial Estate, Coventry, CV3 4LB.
Torque settings:

Flexible hose to front caliper:

22 Nm

Front caliper to hub carrier: 45 Nm

The Brembo rear brake callipers may have the sliding pins overhauled as detailed below, but any signs of

hydraulic leakage from the cylinder indicate that the unit should be replaced.

Rear Calliper Sliding Pins

The sliding bushes and sleeves of the Brembo rear callipers may be replaced without disturbing the

hydraulic connection:

a)

Disconnect the parking brake cable from the calliper.

b)

Remove the cap head bolt securing the bottom guide bush to the hub carrier.

c)

Remove the hex. head bolt securing the top guide bush to the hub carrier, and withdraw the calliper from
the car with the brake hose still connected.

d)

Slide out the lower steel guide sleeve and withdraw the bush/boot from the calliper.  Pull the boots off the
top steel guide bush and slide out the bush from the calliper.

e)

Clean the guide bores in the calliper body with brake cleaner.  Lubricate the new bushes and boots with
silicone grease provided in the repair kit, and reassemble into the calliper in reverse order to disassembly.

f)

Refit the calliper to the hub carrier using Permabond A134 on the threads of both bolts, torque tightening
the two fixings to:
Upper M10 bolt;

45 - 50 Nm (33 - 37 lbf.ft)

Lower M8 caphead; 26 - 30 Nm (19 - 22 lbf.ft)

g)

Reconnect the parking brake cable and operate the footbrake to reposition the pads before driving the
car.

Top guide bush boots

Top guide bush

Lower guide
boot

         j163

Split plastic bush

Lower guide sleeve

Page 39

 Section JJ

Lotus Service Notes

JJ.8A - '08 MODEL YEAR UPGRADE OPTION 

Introduced as an option for some '08 models, is an uprated front brake kit, comprising 4-piston front 

callipers, larger diameter front discs and steel braided hoses. 

Front Callipers: 

At each front corner, the A.P. Racing, alloy, 4-piston front calliper is radially mounted to the front hub 

carrier via an alloy adaptor bracket.  Two reduced head capscrews secure the adaptor bracket to the hub 
carrier, with two capscrews with washers securing the calliper to the adaptor.  Two retaining pins are used to 
locate the Pagid RS14 brake pads, and also secure an anti-rattle spring plate which incorporates a direction of 
rotation arrow. 

Torque figures:  Adaptor to hub carrier; 58 Nm.  Calliper to adaptor; 58 Nm.  Caliper bleed screw; 17 Nm. 

Front Discs: 

The front discs are increased in diameter from 288mm to 308mm, and are cooled by internal curved 

vanes which trail the normal direction of rotation, to result in distinct RH and LH components.  Each disc is 
mounted to its hub via an adaptor 'bell' from which it should not be separated under normal circumstances. 
Torque of disc to bell mounting bolts; 14 Nm.   Note that these discs are fitted only on the front, with standard 
discs on the rear. 

New thickness of the front discs is 26.00mm; minimum service thickness 25.00mm 

Wheel bolts: 

In order to provide sufficient clearance between the 4-piston brake callipers and all road wheel options, 

the thickness of the disc mounting bell at the hub face is increased from the standard 7mm disc thickness to 
11mm.  This requires the use of 2mm longer wheel bolts (C117G6000F) to maintain sufficient thread engage-
ment.  To reduce the possibility of incorrect fitment, both front and rear wheels are secured with the longer 
bolts, with no coded security bolts fitted.  Note that these bolts use the standard spline type socket heads, but 
have a reduced outside diameter of the head. 

Standard bolt; 

B117G6000F 

26mm thread length 

Head outside diameter: 22mm 

Long bolt; 

C117G6000F 

28mm thread length 

Head outside diameter: 19mm 

Braided hoses: 

The steel braided front hoses are connected to the front callipers using a banjo fitting tightened to 25 Nm. 

Page 12a 

   Lotus Service Notes

                Section JJ

Page 13

JJ.9 - BRAKE MASTER CYLINDER

The tandem brake master cylinder is mounted in the front compartment and is secured to the brake servo

by two studs with M8 nuts.  The cylinder uses two pistons to supply the independent front and rear brake
circuits.  The cross-section below is provided for information, but the master cylinder manufacturer does not
recommend any dismantling of the unit, and supplies no replacement parts or internal components.  If the
cylinder is faulty it should be renewed as a complete assembly.

To remove the unit, proceed as follows:

1.

On Exige models, remove the front clamshell (see sub-section BR.6).

2.

Syphon fluid from the reservoir to reduce spillage.

3.

Release the two hoses connecting the master cylinder to the fluid reservoir, and the single hose connect-
ing to the clutch master cylinder, and plug all hoses.  Disconnect the electrical cables from the reservoir
cap, cut the tie wrap and withdraw the reservoir from the mounting bracket.

4.

Release the two brake pipes from the master cylinder, and plug the pipes and ports.

5.

Release the two nuts securing the master cylinder to the brake servo and remove the cylinder.

6.

Refit the master cylinder in reverse order to removal, using NEW locknuts (supplied with a new cylinder)
and tighten to the following torques:
-

Master cylinder fixing nuts; 25 Nm

-

Brake pipes to cylinder; 17.5 Nm

7.

Fill the reservoir with DOT 4 non-mineral type brake fluid, and bleed the complete brake system of air
using standard vacuum assisted, pressure assisted or manual techniques.

Key to Cross-Section

1.

Body

2.

Passage to rear cylinder

3.

Rear cylinder inlet port

4.

Guide bush

5.

Rear piston

6.

Lip seal

7.

Stop washer

8.

Primary seal

9.

Washer

10.

Spring plate

11.

Retaining screw

12.

Stop sleeve

13.

Rear piston spring

14.

Front piston

15.

Secondary seal

16.

Transfer passage

17.

Front piston stop

18.

Front piston spring

j187