What 46 owners told NHTSA about the 2005 Lotus Elise

TL* THE CONTACT OWNS A 2005 LOTUS ELISE. THE CONTACT STATED THAT WHILE DRIVING 40 MPH, SMOKE BEGAN TO EMIT IN AND AROUND THE VEHICLE. THE CONTACT ATTEMPTED TO ENGAGE THE BRAKES BUT THE PEDAL SANK TO THE FLOOR. THE VEHICLE WAS TOWED TO THE DEALER. THE TECHNICIAN DIAGNOSED THAT THE OIL COOLER LINE FRACTURED CAUSING A LEAK AND AS A RESULT, THE OIL COOLER AND BRAKES NEEDED TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS REPAIRED. THE FAILURE MILEAGE WAS 41,187. THE CURRENT MILEAGE WAS 42,250.

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NHTSA RECALL #11V-510. ON 11/11/13 I MADE AN APPOINTMENT FOR 11/18/13 TO HAVE THE REFERENCED RECALL WORK PERFORMED ON MY 2005 LOTUS ELISE AT STAR MOTOR CARS IN HOUSTON, TX. ON 11/18/13 I BROUGHT THE CAR TO STAR MOTOR CARS TO HAVE THE RECALL WORK DONE. TODAY IS 11/26 AND THE WORK HAS NOT BEEN COMPLETED AND STAR MOTOR CARS CANNOT TELL ME A DATE THAT IT WILL BE COMPLETED. STAR MOTOR CARS HAS FAILED TO PERFORM THE RECALL WORK IN A TIMELY MANNER. *TR

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2005 LOTUS ELISE. CONSUMER WRITES IN REGARDS TO DENIAL OF REIMBURSEMENT FOR REPAIR OF VEHICLES OIL COOLER LINE. *SMD THE CONSUMER STATED A RECALL WAS ISSUED FOR THE EXACT PROBLEM HE EXPERIENCED. THE MANUFACTURER CLAIMED THE FAILURE TOOK PLACE OUTSIDE OF THE DATE RANGE AS SET FOR IN THE REIMBURSEMENT PLAN. THE CONSUMER STATED THERE WAS NO EXPLANATION OF HOW THE DATE RANGE WAS SET. HE STATED THE RECALL EXPLAINED THE DEFECT WAS ON LOTUS VEHICLE MANUFACTURED FROM 2004-2006. THE CONSUMER STATED HE PURCHASED HIS VEHICLE IN MARCH 2006. THE FAILURE OCCURRED SIX MONTHS OUT WARRANTY IN NOVEMBER 2009. THE CONSUMER STATED FOR SOME REASON, THE REIMBURSEMENT WINDOW BEGAN OCTOBER 5, 2010.

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FRONT OIL COOLER HOSE BLEW OFF SPRAYING UNDERSIDE OF CAR WITH OIL. PULLED VEHICLE OVER AND TOWED TO DEALER FOR MAINTENANCE FIX. *TR

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RIGHT SIDE OIL COOLER HOSE BLEW OFF WHILE TRAVELING AT 65MPH SPRAYING OIL OVER THE RIGHT BACK TIRE. THE ENGINE SEIZED AND CAR COASTED TO A STOP POSITION ON SIDE OF ROAD. CAR WAS INOPERABLE AND TOWED TO DEALER. *TR

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TL* THE CONTACT OWNS A 2005 LOTUS ELISE. THE CONTACT STATED THAT HE RECEIVED A RECALL NOTICE IN JANUARY 2012 FOR NHTSA CAMPAIGN ID NUMBER:11V510000 (ENGINE AND ENGINE COOLING). THE CONTACT STATED THAT HE TRIED TO GET THE VEHICLE REPAIRED BUT THE MANUFACTURER STATED THAT THEY WERE WORKING ON TRYING TO DETERMINE HOW TO REPAIR THE VEHICLE. THE CONTACT STATED HE WANTED TO GET THE VEHICLE REPAIRED BUT IT WAS TAKING TOO LONG FOR THE VEHICLE TO BE SERVICED UNDER THE RECALL, WHICH HAD EXCEEDED A REASONABLE AMOUNT OF TIME. THE CONTACT HAD NOT EXPERIENCED A FAILURE. UPDATED 8/6/12 *CN UPDATED 08/14/2012 *JS

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OIL LINE FAILURE BY THE FRONT LEFT (DRIVER SIDE) TIRE. WAS TRAVELING STRAIGHT ON THE FREEWAY, NO COLLISION OF ANY SORT. OIL LIGHT CAME ON AND CAR STARTED LEAKING OIL BY THE FRONT TIRE. APPARENTLY A RECALL IS IN EFFECT FOR THIS ISSUE, BUT NO FIX IS AVAILABLE YET. RECALL SUMMARY CAN BE SEEN HERE: HTTP://WWW-ODI.NHTSA.DOT.GOV/CARS/PROBLEMS/RECALLS/RECALLSUMMARY.CFM?RCL_CAMPAIGN_ID=11V510000&PROD_ID=215286&MODULETYPE=VEHICLE&MAKE=LOTUS&MODEL=ELISE&VEH_MODEL_YEAR=2005&SEARCHTYPE=DRILLDOWN NOTE: CAN'T GET EXACT MILEAGE OF CAR BECAUSE IT REQUIRES TURNING THE ENGINE ON. *TR

NHTSA ODI 10450305

WIRING ON AUTO HAS BEEN A MESS SINCE NEW, AUTO TOWED 15 TIMES FOR MECHANICAL REASONS AND ADDITION TIMES TOW TRUCK WAS COMING AND CAR WOULD START. SHIFTER BROKE OFF AT 2,000 MILES, TRANSAXLE WAS REPLACED AT ABOUT 20,000 MILES ALARM SYSTEM, ALTERNATOR,SPEAKERS,TURN INDICATORS, FRONT STEERING BOX (RACK), VEHICLE COMPUTER (SPEED INDICATED ON DASH HAS BEEN AT LEST 15% HIGH SINCE TRANSAXLE WAS REPLACED)-- HAVE ALL FAILED. LOTUS DEALERSHIPS WHERE NEVER ABLE TO LOCATE OR FIX WIRING PROBLEM (FOX VALLEY, AURORA IL ANOTHER LAKE FOREST HAS NO AUTHORIZED LOTUS MECHANIC.) LOTUS USA INC. COVERED MOST UNTIL WARRANTY EXPIRED ,NOW WILL NOT RETURN PHONE CALLS OR E-MAILS (OVER 15 SENT IN THE LAST YEAR AND A HALF.). AUTO NOW HAS 26,666 MILES AND HAS NOT BEEN DRIVEN SINCE AUGUST OF 2010. IT WILL NOT PAST WISCONSIN EMISSIONS SO I AM UNABLE TO GET LICENSE PLATES ALSO IT WILL CHANGE LANES OFF A STRAIGHT LINE WITHOUT WARNING. AUTO WAS NEVER ON A TRACK AND ALWAYS STORED IN A HEAT AND RODENT CONTROLLED AREA. A INDEPENDENT MECHANIC THAT WORKED ON AUTO STATED "THE WIRING HARNESS APPEARS TO HAVE BEEN PULLED AND INSTALLED THROUGH OUT THE AUTO WITH OUT REGARD TO SHARP EDGES OR CARE IN ANYWAY", HE FOUND NO RODENT DAMAGE.

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OEM OIL COOLING LINE CRIMP LET GO THAT IS IN FRONT WHEEL WELL TO OIL COOLER. ENGINE OIL POURED ALL OVER FRONT TIRE AND BRAKES. EVEN AT 15 MPH I LOST CONTROL. THIS WOULD HAVE BEEN FATAL IF DRIVING AT HIGHWAY SPEED. *TR

NHTSA ODI 10427071

THIS IS A COMPLAINT FOR A 2005 LOTUS ELISE OIL LINE FAILURE. I PREVIOUSLY REPORTED TWO OIL LINE FAILURES TOGETHER BUT IN RETROSPECT SHOULD HAVE REPORTED THEM INDIVIDUALLY AS THEY OCCURRED AT SEPARATE TIMES. THE FIRST OIL LINE FAILURE OCCURRED ON 3/29/2010. I CAME OUT TO MY CAR IN THE PARKING LOT AND THERE WAS A LARGE PUDDLE OF OIL UNDER IT. I DID NOT EVER SEE A DROP OF OIL FROM THE CAR PREVIOUSLY. I PAID 1,066 TO GET THE DRIVER SIDE OIL LINE REPAIRED. I WAS TOLD THAT THE PASSENGER SIDE OIL LINE SHOULD BE FIXED BUT I WAS NOT TOLD THAT IF IT FAILED WHILE DRIVING THAT I COULD POTENTIALLY LOSE CONTROL OF THE CAR. THE PASSENGER SIDE OIL LINE DID INDEED FAIL 4 MONTHS LATER BUT THIS TIME WHILE I WAS DRIVING ON A HIGHWAY GOING 55 MPH. THE ENTIRE OIL CAPACITY OF THE ENGINE SPRAYED ONTO THE PASSENGER SIDE FRONT AND REAR TIRES AS WELL AS THE WINDSHIELD. NOT ONLY WAS IT LIKE DRIVING ON A SHEET OF ICE, I COULD NOT SEE ANYTHING. LUCKILY THERE WAS NO ONE IN THE LANE NEXT TO ME AS I SLID INTO IT. I WAS ABLE TO GAIN CONTROL OF THE CAR AND PULL OVER. BY THE TIME I PULLED OVER THE ENGINE WAS RUINED REQUIRING ME TO PAY APPROXIMATELY 8,000 FOR A NEW ENGINE AND NEW OIL LINES. I HAVE PICTURES OF THE CAR SHOWING THE ENTIRE PASSENGER SIDE OF THE CAR COVERED IN OIL. UPDATED 08-29/11 *BF *KB UPDATED 05/03/12

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TL* THE CONTACT OWNS A 2005 LOTUS ELISE. THE CONTACT STATED THAT OIL WAS LEAKING FROM THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER HOWEVER, THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 14,000 AND THE CURRENT MILEAGE WAS 14,200. THE RIGHT REAR OIL LINE AT THE METAL FITTING IS CURRENTLY LEAKING OIL. UPDATED 10/28/11

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I BOUGHT MY CAR USED FROM A PRIVATE SELLER IN PENNSYLVANIA. AFTER DOING THE FIRST OIL CHANGE MYSELF I NOTICED THE WAS OIL SEEPING FROM ONE OF THE OIL LINE FITTINGS AT THE SANDWICH PLATE. AFTER SOME RESEARCH I HAVE FOUND THIS IS A COMMON PROBLEM AMONG LOTUS' YEARS 2005-2007, AND CAN RESULT IN FAILURE OF THE OIL LINE AT SPEED CAUSING A CRASH OR FIRE. IT HAS ALSO BEEN BROUGHT TO MY ATTENTION THAT THE NHTSA IS PERFORMING AN INVESTIGATION ON THIS ISSUE. *KB

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TL* THE CONTACT OWNS A 2005 LOTUS ELISE. THE VEHICLE WAS TAKEN TO THE DEALER FOR A ROUTINE OIL CHANGE; HOWEVER, THE TECHNICIAN STATED THE OIL LINE WAS LEAKING AT THE FITTING WHERE IT CONNECTS TO THE ENGINE AND IT NEEDED TO BE REPLACED. THERE WAS AN OPEN INVESTIGATION UNDER NHTSA ACTION NUMBER: PE11022 (ENGINE AND ENGINE COOLING ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSE) THAT MAY BE RELATED TO THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 10,881.

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DURING A TIRE ROUTINE TIRE CHANGE, IT WAS OBSERVED THAT THERE WAS AN UNUSUAL OIL STAIN CREEPING UP THE INSIDE OF THE FENDER WELL ON THE LEFT FRONT OF THE VEHICLE. IT WAS LATER DETERMINED THE OIL COOLER WAS LEAKING AT THE FITTING AND A NEW FITTING WAS INSTALLED TO CORRECT. THE LEAK OCCURRED RATHER SUDDENLY AS THE CAR HAD JUST BEEN IN THE BODY SHOP TO HAVE SOME MINOR BODYWORK FIXED (NON-STUCTURAL AND NOT ABLE TO HAVE CAUSED THE LEAK). AT THE TIME OF THE BODYWORK REPAIRS TIME, LESS THAN 300 MILES PRIOR, THE LEAK WAS NOT PRESENT. IF THE LEAK HAD BEEN PRESENT, THE SUBSEQUENT OIL WOULD HAVE CAUSED POOR PAINT FINISH. WHICH WAS NOT THE CASE. DID NOT THINK TO REPORT THE INCIDENT UNTIL NOW, BECAUSE I JUST BECAME AWARE OF A NY TIMES ARCTICLE REPORTING ON NHSTA INVESTIGATION OF OTHER SIMILAR MODEL YEAR LOTUS ELISE/EXIGE CARS EXPERIENCING THE SAME ISSUE.

NHTSA ODI 10415874

FAILURE OF OIL LINE CONNECTOR. SPREAD OIL OVER FRONT BRAKE, SO AS TO MAKE CAR STOP POORLY. HAS HAPPENED TWICE: ONCE WHEN CAR WAS 1 MONTH OLD, NOW 6 YRS LATER. *TT

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MY CAR IS AN EARLY 2005 LOTUS ELISE WITH TWIN OIL COOLERS. THE BYPASS HOSE CONNECTING TO THE DRIVER SIDE OIL COOLER STARTED TO LEAK OIL AT A FAIRLY FAST PACE. THIS HOSE CONNECTS FROM THE LEFT OIL COOLER TO THE RIGHT COOLER UNDERNEATH THE CLAMSHELL. COSTS TO FIX THIS SERIOUS ISSUE OUT OF WARRANTY ARE EXTREMELY HIGH AS THEY RECOMMEND REPLACING THE ENTIRE OIL COOLER AND HOSE SYSTEM. THERE ARE NOW NUMEROUS COMPLAINTS OF THE SAME OR SIMILAR (BASED ON HOSE AND/OR TWIN/SINGLE OIL COOLER SETUPS) ON VARIOUS FORUMS AND SUBMITTED COMPLAINT FORMS TO THE US DOT NHTSA.

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DRIVING UNDER NORMAL CONDITIONS THROUGH CITY TRAFFIC WHEN THE OIL INDICATOR LIGHT CAME ON. PULLED OVER TO THE SIDE OF THE RODE AND CHECKED THE OIL LEVEL. SHOWED IT WAS EMPTY WITH OIL SPILLING ON THE GROUND. TOWED IT TO A REPAIR SHOP TO DISCOVER THAT THE OIL HOSE FITTING HAD BROKEN OFF THE ENGINE CAUSING THE OIL LOSS. THIS COULD HAVE RESULTED IN A TOTAL LOSS OF ENGINE FUNCTION HAD I NOT PULLED OVER. I HAD THE OIL HOSE REPLACED AND REPLACED THE REMAINING HOSES AS WELL.

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WHILE DRIVING AT HIGHWAY SPEEDS I SUDDENLY SMELLED OIL AND LOOKED DOWN TO SEE MY OIL PRESSURE LIGHT COME ON. I IMMEDIATELY PULLED OVER AND FOUND OIL COMING OUT OF THE RIGHT FRONT SIDE OF THE CAR ONTO THE RIGHT FRONT AND REAR TIRES. UPON HAVE THE VEHICLE TOWED TO A REPAIR SHOULD THEY FOUND THAT THE INCOMING OIL LINE INTO THE PASSENGER SIDE OIL COOLER HAD COMPLETELY SEPARATED FROM THE CONNECTOR. *TR

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AFTER READING OF SERIOUS OIL LINE FITTING FAILURES ON MY MODEL OF CAR, I INSPECTED MY OIL LINE FITTINGS AND FOUND ONE THAT WAS LEAKING. IF THIS FITTING HAD FAILED TO THE POINT WHERE THE HOSE CAME OFF (WHICH HAS HAPPENED TO OTHERS), IT WOULD HAVE SPRAYED OIL IN FRONT OF MY RIGHT REAR WHEEL, WHICH COULD HAVE CAUSED LOSS OF VEHICLE CONTROL, AND RUINED MY ENGINE. I REPAIRED IT WITH A NEW FITTING THAT IS MORE SECURE THAN THE FACTORY FITTING. I ALSO MADE MEASUREMENTS (USING DIGITAL CALIPERS) OF THE ORIGINAL FITTING CRIMP BEFORE I REMOVED IT, AND ANOTHER FITTING ON THE CAR THAT WASN'T LEAKING OIL. THE MEASUREMENTS SHOWED THAT THE LEAKING FITTING WAS NOT CRIMPED AS TIGHTLY AS THE ONE THAT WASN'T LEAKING. I RECOMMEND THAT THE ORIGINAL CRIMP SPECIFICATIONS BE REVIEWED (THE ORIGINAL SPECIFICATION MAY NOT BE TIGHT ENOUGH), AND THAT A RECALL BE ISSUED TO, AT A MINIMUM, MEASURE THE ACTUAL CRIMP SIZE ON ALL SIX OIL LINE FITTINGS ON THE CAR TO SEE IF ANY ARE NOT SUFFICIENTLY CRIMPED. IF THEY ARE NOT, THEN THEY SHOULD BE REPLACED OR RECRIMPED (IF THAT CAN BE DONE PROPERLY). *TR

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VEHICLE INSPECTION FOUND OIL IS LEAKING AT OIL HOSE CONNECTOR DUE TO INSUFFICIENT CRIMPING OF ADAPTER TO OIL HOSE. EVENTUALLY THIS WILL LEAD TO OIL HOSE DISCONNECTION AND A LOSS OF ENGINE OIL.

NHTSA ODI 10391288

MY 2005 LOTUS ELISE EXPERIENCED A COOLANT LEAK IN THE P/N A12E0017F ALUMINUM U-TUBE DUE TO EXCESSIVE RUBBING ON A OIL FITTING THAT THE TUBE WAS RESTING ON. DUE TO THE ENGINE VIBRATION AND SHAKING, THE U-TUBE WORE THROUGH THE TUBE WALL COMPLETELY ALLOWING COOLANT TO LEAK OUT. THE U-TUBE IS LOCATED ON THE FRONT SIDE OF THE ENGINE AND RUBS ON A OIL LINE FITTING. BASED ON AN ONLINE FORUM (LOTUSTALK) AND OTHER LOTUS ELISE/EXIGE OWNERS, THE U-TUBE RUBBING IS NOT AN ISOLATED. APPARENTLY, SOME ELISES/EXIGES HAVE THE U-TUBE ZIP-TIED TO THE OIL LINE FITTING, BUT THE RUBBING IS STILL APPARENT AND ONLY A MATTER OF TIME BEFORE A COOLANT LEAK WILL OCCUR. MY ELISE WAS NOT ZIP-TIED, WHICH NO DOUBT ACCELERATED THE WEARING AND RESULTING LEAK. I DECIDED TO MAKE A REPORT SINCE IT LOOKS LIKE LOTUS OWNERS ARE STILL IDENTIFYING THE RUBBING AND APPLY DO-IT-YOURSELF FIXES. I REPAIRED MINE AT MY OWN EXPENSE AND STARTED A THREAD ON LOTUSTALK TO HELP OTHER OWNERS PROTECT THEIR CARS FROM EVER LEAKING LIKE MINES. *TR

NHTSA ODI 10389986

FAILURE: BROKEN TOE LINK BOLT. EVENT'S LEADING TO THE FAILURE: NORMAL DRIVING OF THE CAR ON PUBLIC STREETS. CONSEQUENCES OF THE FAILURE: REAR WHEEL WILL MOVE FREELY CAUSING TOTAL LOSS OF CONTROL OF THE CAR. THIS CAN CAUSE AN ACCIDENT FROM MINOR INJURIES TO BOTH THE CAR'S OCCUPANTS AND INNOCENT DRIVERS AROUND THE CAR TO SEVERE PENALTIES SUCH AS DEATH(S). WHAT WAS DONE TO CORRECT THE FAILURE: PROPER REMOVAL AND CLEANING OF GALVANIZED CLUMPS (MANUFACTURE DEFECT) WHERE THE TOE LINK BOLTS TO THE CHASSIS. MOREOVER, REPLACEMENT OF THE TOE-LINK JOINT, NUTS AND BOLTS, AND ENSURE THEY ARE PROPERLY TORQUED TO MANUFACTURES SPECIFICATION. *TR

NHTSA ODI 10386462

2005 LOTUS ELISE. THE OIL LINE RELEASED FROM ITS FITTING ON THE FRONT RIGHT OIL COOLER WETTING THE TIRE WITH OIL RESULTING IN A LOSS OF CONTROL. THE CAR SPUN AND LEFT THE ROAD. NO DAMAGE OCCURRED AND THE CAR WAS TOWED FROM THE MEDIAN AND THE LINE WAS REPAIRED. I SELECTED THE YES RESPONSE TO WAS THERE A CRASH BASED ON THE CAR LEAVING THE ROAD. *TR

NHTSA ODI 10383910

OIL LINE FAILURE IN LOTUS ELISE - GOT RED "ENGINE OIL PRESSURE LOW" LIGHT, PULLED OVER, CLAMP/HOSE HAD BLOWN OUT AND OIL SPILLED OUT EVERYWHERE. *LN

NHTSA ODI 10379547

ON STARTING MY CAR IN THE MORNING, THE PASSENGER SIDE OIL COOLER HOSE FROM THE ENGINE TO THE FRONT OIL COOLER SEPARATED AT THE REAR CRIMP, QUICKLY DRAINING ALL OF THE OIL. THE OIL WARNING LIGHT CAME ON, AND AS I SHUT THE ENGINE OFF THE ENGINE MADE A COUPLE OF RATTLING NOISES. ON ATTEMPTING TO REPLACE THE DEFECTIVE HOSE, I HAVE BEEN UNABLE TO FIND THE PART IN STOCK, LEADING ME TO HAVE NEW HOSES MADE BY A HYDRAULIC SHOP. THE FAILURE IS AT A MINIMUM RESPONSIBLE FOR A COSTLY REPAIR AND CLEAN UP, THAT MAY TAKE SEVERAL WEEKS DUE TO PARTS AVAILABILITY, AND IN A WORST CASE MAY CAUSE AN ACCIDENT DUE TO OIL ON THE TIRES, AS WELL AS ENGINE FAILURE DUE TO LOSS OF OIL. MY CAR IS A 2005 ELISE WITH 55,000 MILES. *TR

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