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Lotus Service Notes Section CK
CK.5 - SUSPENSION DISASSEMBLY/ASSEMBLY
The suspension may be disassembled without the use of any special tools other than spring compressor
clamps if the spring and damper are to be separated. With the car on a wheel free lift and with the front wheels
removed:
1. Remove the wheelarch liner(s) as appropriate.
Hub Unit
2. Remove the two bolts securing the brake calliper to the hub carrier, release the flexible hose from the top
wishbone, and support the calliper aside without straining the brake hose. Release the single countersunk
screw, and remove the brake disc.
3. Release the harness connector from the wheel speed sensor, release the harness from any suspension
components, and secure the harness aside. Release the single screw securing the wheel speed sensor,
and withdraw the sensor from the hub carrier.
4. Release the four hex. head securing bolts and withdraw the hub unit from the hub carrier. Note that this
unit is common to all four wheels.
Hub Carrier
5. Remove the nut securing the track rod ball joint into the steering arm, and use a ball joint splitter to sepa-
rate the joint from the arm.
6. Remove the nut securing the top swivel joint to the hub carrier, and use a ball joint splitter to separate the
joint.
7. Remove the nut securing the lower swivel joint to the hub carrier, and use a ball joint splitter to separate
the ball pin from the carrier. Lift the carrier and hub unit from the car.
Damper and Spring
8. If the damper and spring are to be separated, it is recommended to remove the complete assembly of
spring/damper/top mounting bracket from the car in order that spring compression may be carried out in
the safest manner.
Remove the 4 bolts securing the top mounting bracket to the subframe, and the single bolt securing the
lower end of the damper to the bottom wishbone bracket. Withdraw the assembly to a workbench.
9. Using spring compressor clamps and taking all suitable safety precautions, unload the spring seats and
remove the bolt securing the top end of the damper to the mounting bracket.
10. Separate the spring, damper and top bracket, noting the spring top seat cushion, and unload the spring
clamps.
Upper Wishbone
11. Release the 'P' clip securing the brake hose to the wishbone, and the front and rear pivot bolts, and with-
draw the wishbone from the subframe. The captive nuts for the pivot bolts are retained in channels in the
chassis extrusions, replacement of the nutplate for the rear pivot requiring removal of the crash structure
joining plate.
Note that the steering swivel ball joint is retained in the wishbone by a swaging operation, and is serviced
only as part of the upper wishbone assembly. For pivot bush replacement, see CK.3.
Lower Wishbone
12. To aid re-assembly, match mark the eccentric cam adjuster positions at both pivot points for the lower
wishbone. Release the anti-roll bar drop link from the wishbone, noting that a 5mm hexagonal socket is
provided in the end of the ball pin stud to aid this process. Remove both pivot bolts and eccentric cam
adjusters, and withdraw the wishbone.
Note that the steering swivel ball joint is retained in the wishbone by a swaging operation, and is serviced
only as part of the lower wishbone assembly. For pivot bush replacement, see CK.3.
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