Replacing the bushings on a Lotus Seven Series 3 front suspension.

[EdWills]

I decided to replace the nylon bushes, dished washers and spacing tubes in the trunnions on my Lotus Seven Series 3 lower front suspension.  I had a spare service kit from Rimmer Bros, and followed the diagram included in with the kit.  I assembled the unit as shown in the diagram, but it would not fit in between the lugs of my lower 'A' arm/wishbone.  The measurement was reading as 1.78 inches total width with the trunnion and assembled kit on my digital caliper.  The inside measurement between the outermost lugs on the wishbone should be 1.5 inches according to a diagram kindly posted on the web, and also as per my wishbone (Arch/Caterham manufactured, and fusion welded, not braze welded, as my Lotus originals were. Note: Braze welded suspension components are illegal in my Province in Canada, and possibly others. My Lotus braze welded originals had been 'butchered' by the second owner to attach lugs for towing the car in case of breakdown at the race track).

I checked my Standard Triumph Spitfire Mk.1 and Mk.2 parts book, and way back when these were manufactured alongside the Triumph Herald that Lotus used parts from for the front suspension on the Series 2 and 3 (and very early Caterham 7s), the outside cupped spacer/washer was never used.  Tony Weale in his book 'Lotus Seven' also shows that the outermost cupped washer was not used. On very early Triumph Herald cars, the cupped washers (inside and outside) were not an included part as shown in a very early Triumph Herald manual that I also have.  It would seem that the outer cupped washer was for addition to later Spitfires, Vitesses etc., to perhaps better protect the square section rubber ring placed onto the nylon bush.  The Series 4 had 2-part wishbones (on both upper and lower) so fitting the entire kit is not a problem. The only way to fit the 'newest' kit with the 4 cupped washers, the nylon bushes, and the spacing tubes, would be to open up the space between the lugs on your lower wishbone.  These are heavy gauge steel, and some bending force would be required. If you do it wrong, the bolt may not fit correctly. It's not very much to open up the gap, but you takes your chance as they say, and it isn't original..... So, if you need to replace the trunnion bushing set-up, just leave off the outer cupped washer, and it should fit nicely. Cheers Will.

Lot7Susp.pdf

[IamScotticus]

My 95/96 Crossflow Live Axle trunnion spacing is slightly over 1.5" spread out an additional 1/16 with the cupped washers in place.

The damper spacing is 1.25".

Edited May 23, 2024 by IamScotticus

[jbcollier]

Yup, the washers don't fit with the stock Lotus arms -- and probably early Caterham ones.

[EdWills]

Hi. Unfortunately, a typing error occurred regarding the measurement of the complete bushing kit assembly installed on the trunnion.  It should have read 1.578 inches.My apologies. Will.