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Discussion Starter · #1 ·
Although this problem pertains

Although this problem pertains to my "resident" Lotus Elan S2, that I promised a friend I'd get sorted out for him, the problems found could easily apply to any older Ferrari...

The symptoms and history are as follows:

The vehicle has been driven 1,000 miles in the last 10 years...
Twenty some-odd years ago, some sort of a major resoration has been done...
The front bake rotors are .120 below minimum thickness, though the pads appear new.
The brake pedal is reasonably firm, but the owner says the car doesn't stop very well.

Repairs and observations, thus far.

-Replace front brake rotors and pads.
-Caliper pistons are very stiff to push back in...and will only move if the brake bleeder is opened.
-RF caliper has a seized inner piston...and again the outter piston will only move if the bleeder is opened
-Remove front brake hoses for inspection
-Date coded 05/1981...Ouch!
-Air flow though hoses indicate substantial restriction.

Remaining action to be taken:
Rebuild front calipers...and replace brake hoses.

And I thought this would be just a simple repair. Anyone ever done the rear brakes on one of these cars? Looks like a barrel of fun, in that the rotors are inboard!


Discussion Starter · #2 ·
Just like the Jaguars with rea

Just like the Jaguars with rear inboards. Not difficult only a PIA. Drop the halfshafts to pull the rotors. Should be able to pull 2 bolts to remove the cal. Just takes time.

Discussion Starter · #3 ·
Hi David,

All work on the r

Hi David,

All work on the rear drive train of the "Baby" Elans is tough. Ever try to remove the rear end assembly?

The Elan is fitted with outboard disks in that the calipers are fixed to the rear hub, but they are mounted differently than most. The rear disks are mounted to the 3-ears on the input side of the axle, making them more inboard then normal for outboard disks. The disks are retained by the same three bolds that attach the Rotoflex joint to the axle. Two things make removal of the disk difficult.

1. The disk is mounted to the axle ears on the outboard surface of the ears.

2. The modified A-arm is strengthened by a longatudinal (front to back orientation) tube in close proximity to the inboard surface of the disk, restricting removal of the disk.

To remove the disk according to the workshop manual:

1. Remove the rear wheel.
2. Lower the outer end of the wishbone and push down to clear disc.
3. Remove the brake caliper.
4. Remove the outboard Rotoflex coupling noting that three of the retaining bolts also secure the brake disc.
5. Turn disc to clear outboard drive shaft (axle- Bill) and remove.

I guess step 5 is the key. Because the disk is mounted to the outboard surface of the axle ears, it needs to be rotated relative to the axle to remove.

I hope this helps.

Discussion Starter · #4 ·
Hi Bill,

Urban folklore is

Hi Bill,

Urban folklore is a funny thing. I asked a few Lotus "experts" about what I was getting in to...All of them said not to get involved with the car, as the rear brakes usually turn into a major project, being incredibly time consuming.

Long and short...the first side I did took me 30 minutes to have the caliper off and the rotor on the floor. The second side, well a mere 20 minutes to totally disassemble, once I figured out that you needed to drop the control arm at the hub. The twist and turn part of the rotor removal did take a bit of thought to figure out. Very crafty design!

All and all, nowhere near the trouble I thought...
Appreciate your input, Bill.

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