jlumba81 Posted May 17, 2011 Share Posted May 17, 2011 '04 SV zetec svt w/ t-9 5 speed. There's a clunk when I upshift that I haven't been able to track down yet. I've checked the driveshaft ujoints and the rear suspension bushing and there wasn't any movement. Also have a minor leak from the transmission where the speedo gear goes in. Can anyone give me a part # for it or know of a website that has them? Also how do you check the fluid level on the transmission? There were several posts about taking the top plate off, but it looks like on the SV the plate is right under the firewall. Link to comment Share on other sites More sharing options...
Ian7 Posted May 18, 2011 Share Posted May 18, 2011 Re: clunk - if it happens as you let the clutch out and the torque load goes back in to the system, could be anywhere from the engine mounts back to the rear suspension. Also possible that you wont find "looseness" by hand with weight-on-wheels either, but shows up under torque. Tranny oil level - can only speak for a Quaife box, on mine there's a filler port on top, and a side plug that sets the level (pour in top until it comes out the side). Link to comment Share on other sites More sharing options...
jlumba81 Posted May 18, 2011 Author Share Posted May 18, 2011 I had the 7 up on jackstands and used a 24" prybar to check the bushings. Still need to check the engine mounts and transmission mount. Link to comment Share on other sites More sharing options...
jlumba81 Posted May 18, 2011 Author Share Posted May 18, 2011 Well I ended up ordering the speedo gear oil seal from burtonpower.com. I ordered an extra so I have something I can take to the local auto parts store to match up in case I need another one. Link to comment Share on other sites More sharing options...
Croc Posted May 18, 2011 Share Posted May 18, 2011 Hi Jude, The gearbox fluid level was checked about 1.5 years back when it and the engine came out to get the mystery metal lump out of the bellhousing. all was good then. Not sure how to do it with transmission in place but I bet there is an answer on blatchat. Re the clunk, a couple of thoughts: 1) Can you identify whether it is driveline or within gearbox? 2) Is it all gears? 3) any sense of whether it is front or back - maybe using a buddy to listen from outside the car when starting off in first? Or running it on rollers through the gears to sense the sound from outside the car. My initial reaction for most likely is check engine mounts, loose/failing UJs, and check for broken de dion. I rate these as more likely given what you experienced on the way home. The last remote possible idea is diff backlash. As an aside, a friend of friend who is a keen car guy in Juneau has seen you about town and plans to chase after to chat when he sees you next. I think he has a classic Porsche 911 (one of two in Juneau I am told). He says the seven looks cool and that you have been the talk of the town. Cheers Link to comment Share on other sites More sharing options...
bsimon Posted May 18, 2011 Share Posted May 18, 2011 Jude, If the clunk is on every gear change, 1-2, 2-3, 3-4, etc. then it's probably not the gearbox. Check the drive shafts, prop shaft, diff backlash, diff mounts, and motor mounts. Jack up the rear end and rotate the rear wheels back and forth in and out of gear to see if you can isolate the clunk noise. Link to comment Share on other sites More sharing options...
Kitcat Posted May 18, 2011 Share Posted May 18, 2011 (edited) I would check motor mounts first. They are notoriously fragile and every Cat owner I know has replaced theirs at least 1x, if not more. Do a search for "transmission fluid" and read the 2nd post for some info on the T9 transmission. Edited May 18, 2011 by Kitcat Link to comment Share on other sites More sharing options...
RossD Posted May 18, 2011 Share Posted May 18, 2011 http://www.lotusowners.com/Miscpics/Type%209-Ngearbox.pdf Repair manual courtesy of LOONY Lotus website Link to comment Share on other sites More sharing options...
jlumba81 Posted May 19, 2011 Author Share Posted May 19, 2011 It clunks in all gears. I still need to look at the motor and transmission mounts. I'll probably take a look at the diff cause I want to check out the fluid level. I have seals for the speedo gear coming in and redline mt-90 gear oil. So far I've been driving the 7 everyday to work except for 1 week where it was all rain and I didn't have the full weather top yet. Next upgrades I plan on doing are some heat wrap on the headers and some insulation on the pedal box. Thanks everyone for the feedback. Link to comment Share on other sites More sharing options...
jlumba81 Posted May 19, 2011 Author Share Posted May 19, 2011 (edited) Well just came back from a quick run to home depot. Under very light throttle there's a grinding noise, but it goes away under more throttle. So I think it may be the diff going bad or in need of adjustment. Anyone know where to get a diff rebuild kit and/or shim kit? And just in case a new ring gear/crown wheel and pinion? I'll have to wait for some good weather until I can pull out the diff to check the backlash. Does anyone have a backlash spec handy? Hmm...just did a google search and it seems that some differential noise and backlash is normal. Well I guess the only way to make sure is to open it up and bust out the marking compound and dial gauge. Always more questions popping up. What's the reccomended fluid for the diff w/ a lsd? Edited May 19, 2011 by jlumba81 Link to comment Share on other sites More sharing options...
bsimon Posted May 19, 2011 Share Posted May 19, 2011 (edited) Sierra Diff Manual There are some special tools required. They aren't essential if you have experience setting pinion depth with die maker's bluing. edited to add: When you have the diff out, that's a good time to replace the cheesy Caterham Hookes joints in the propshaft. Any reputable drive line overhauler can set you up with new Dana/Spicer joints and balance job for $150 or so. Since the Caterham propshaft is essentially in-line and has no angular departure, the joints wear very rapidly. Edited May 19, 2011 by bsimon Link to comment Share on other sites More sharing options...
MHKflyer52 Posted May 19, 2011 Share Posted May 19, 2011 Before pulling everything apart you might wan to check the fluid levels in the trans and diff. You might also want to check the CV joints as the will make a grinding noise if the boot has been split and the grease is missing or they could be worn out. Hope this helps and you get it figured out as it is just part of 7 ownership and what make them so fun. Link to comment Share on other sites More sharing options...
athens7 Posted May 20, 2011 Share Posted May 20, 2011 What's the reccomended fluid for the diff w/ a lsd? I use Redline 75W90 synthetic GL5 hypoid gear oil with LSD friction reducers. I have always had a clunk when I'm a little sloppy with my upshifts returning to throttle but there is no trash in my gear oil and it is not burned. Most will tell you that Caterham LSDs are a bit noisy and clunky; the post ZF LSDs can be more than a bit, according to Blatchat. On an '04, it should be a ZF, like mine. The Redline MT-90 is a good choice for the transmission. As to checking transmission fluid levels, I think the best solution is to remove the top cover, drill a hole in one of the front corners, weld in a bung, and install a threaded plug. Finally, fabricate an appropriate length dipstick to measure the level. I can take a couple of photos of my set up, if you like. Link to comment Share on other sites More sharing options...
breezy7 Posted May 20, 2011 Share Posted May 20, 2011 Pictures please Brad, I've put off putting doing the same mod for years. Is the top plate just a cover? Nothing is attached to the cover on the inside of the transmission? Did you make the opening large enough to get a siphon hose in for draining the gear oil? Mike Link to comment Share on other sites More sharing options...
jlumba81 Posted May 20, 2011 Author Share Posted May 20, 2011 Is the top cover removable w/ the transmission still in the car? The welded bung tip sounds like a good idea. I've also seen aftermarket alloy top covers w/ fill holes going for around $85. How do you take off the transmission tunnel cover off the ebrake handle? Saw the alloy lid on this site: http://www.bearingkits.co.uk/product_info.php?currency=USD&cPath=76_90&products_id=401&osCsid=fad5779367dc63fc0b4638e1982cd515 Link to comment Share on other sites More sharing options...
jlumba81 Posted May 20, 2011 Author Share Posted May 20, 2011 bsimon, what's the tyipical mileage before a caterham ujoint fails? I don't have a shop locally that does auto driveshafts. I'll have to look around to see if a boat shop can do it or just ship it out to get it worked on. Probably be a fall/winter upgrade. Link to comment Share on other sites More sharing options...
Croc Posted May 21, 2011 Share Posted May 21, 2011 (edited) Is the top cover removable w/ the transmission still in the car? The welded bung tip sounds like a good idea. I've also seen aftermarket alloy top covers w/ fill holes going for around $85. How do you take off the transmission tunnel cover off the ebrake handle? Saw the alloy lid on this site: http://www.bearingkits.co.uk/product_info.php?currency=USD&cPath=76_90&products_id=401&osCsid=fad5779367dc63fc0b4638e1982cd515 Here are some Blatchat topics that address some of the questions you are raising. I always find doing searches in the Tech section gives me an answer that some sevener has faced before me. If that does not work then there are also many friendly guys here with a wealth of knowledge: Tunnel top removal - simple answer is loosen handbrake cable, stand handle up vertical, remove gear knob and check that screws are removed at the rear of the tunnel top (I think I put them back in the last time I had the engine out). http://www.blatchat.com/t.asp?id=201437 Gearbox oil top up http://www.blatchat.com/t.asp?id=159135 http://www.blatchat.com/t.asp?id=190698 http://www.blatchat.com/t.asp?id=183709 Diff Removal http://www.blatchat.com/t.asp?id=156137 Diff Oil Check http://www.blatchat.com/t.asp?id=183709 Also for the lid, I think BGH also offer a replacement part: http://www.bghgeartech.co.uk/html/bgh_home.html Edited May 21, 2011 by Croc Link to comment Share on other sites More sharing options...
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