Lotus elan rear strut hub and tube.

How to remove and replace
Lotus elan rear strut tube.

Today we explore the removal and replacement of the rear strut tube of the Lotus elan.

The day could arrive soon when you may need to tackle this job, the videos below outline how to carry out that operation using the correct tools and methods. There could be a reason to think that this job could not be tackled by the DIY home mechanic, but you might be surprised, it is actually not all that difficult.

There is an old saying that says; “fools rush in where angels fear to tread.” But, if one is competent with one’s own workshop ability and mechanical knowledge, then there is no reason to think that you can’t do this job yourself.

Yes, there are some important tools and equipment required, but its certainly not beyond the realms of possibility.
So let’s explain to you the how, what and why.

Firstly, the tools required:
Garage press,
Pressing mandrels, various collars, press rod lengths and diameters to help press the tube out of the cast aluminium housing and also to press the tube back in again.

Heating device: Best choice: Oxy/Acet torch, or LP gas and Oxy heating torch. Really small gas torches may struggle to deliver a sufficient amount of heat in a short time frame.

The first and second video explain the process and the method and technique required to remove the strut tube without damaging the aluminium hub housing, or the tube.

There are five videos in total. they are each about five minutes in length, in an effort to cover all of the bases, we found that we couldn’t make them any shorter. So make your self a coffee and sit back to learn and enjoy.

With strut assembly correctly set up in the press, heat is applied to the aluminium housing to expand the metal so that the tube can be pressed out with out damaging the critical tolerances of the shrink fit joints. DO NOT press tube out when cold, the aluminium housing must be warmed up (Hand touch).

Aluminium is a delicate, soft metal, it must be handled with care, once the tube is out of the housing both can be carefully cleaned and inspected.

The aluminium housing is now set up and held/secured by press plate fixture in readiness to press the steel tube back, but first the aluminium must be pre-heated in order for the tube to be inserted and pressed home.

The last video, and a word about (None commercial) various products for the de-greasing and cleaning of metal, and application of a special compound to guard against future corrosion.

Please also note that many cheap garage presses do not have a press bed with a wide throat, the press shown above was engineered and built in our workshop which included a 7.5″ width between the bed rails, the cross plates are one inch thick steel off cuts sourced from a local heavy engineering workshop. A wider press bed will be required to accommodate the standard elan fixed spring perches.

We trust that you have enjoyed the videos, and if/when you might need to do this job you will be better informed about what it takes to do this job with out damaging expensive components.