2004 LOTUS EXIGE

Typical onset: 40,000-80,000 mi

Symptoms: Metallic knocking on cold start that worsens when warm, Low oil pressure warnings during hard cornering or track use, Sudden catastrophic failure with complete loss of power

Fix: The 2ZZ suffers oil starvation under sustained high-G cornering, starving rod bearings. Fix requires complete engine rebuild with upgraded oil pump, baffled pan, and accusump system. Budget 40-50 hours for removal, rebuild, and reinstall in the Exige's mid-engine bay. Many owners go with full forged internals while it's apart.

Estimated cost: $8,000-15,000

Typical onset: 30,000-60,000 mi

Symptoms: Severe clunking during shifts, especially 1st to 2nd, Excessive drivetrain movement visible from outside, Difficult gear engagement when cold

Fix: The rear gearbox mount disintegrates from heat and vibration. Requires dropping the entire rear subframe—roughly 6-8 hours labor. Upgraded polyurethane mounts last longer but transmit more NVH. Always inspect the mount bracket itself for cracks while you're in there.

Estimated cost: $800-1,400

Typical onset: 50,000-90,000 mi

Symptoms: Whining or grinding noise from supercharger, Loss of boost pressure, Oil residue around supercharger snout, Check engine light with lean codes

Fix: The Eaton M45's internal oil breaks down or the nose drive coupler fails, both require supercharger removal and rebuild. Factor 8-10 hours for removal in the tight engine bay, plus rebuild or replacement. Many upgrade to aftermarket units while addressing this. Preventive supercharger oil changes every 30k prevent most failures.

Estimated cost: $2,000-4,500

Typical onset: 50,000-100,000 mi

Symptoms: Transmission fluid puddles under vehicle, Burnt smell after spirited driving, Notchy or grinding shifts when gearbox overheats

Fix: Hard lines corrode and flex lines crack where they route near the exhaust. Requires 3-4 hours to access and replace. Some owners delete the cooler entirely if not tracking, but this shortens synchro life. Upgrade to braided stainless lines if keeping the system.

Estimated cost: $600-1,000

Symptoms: White smoke from exhaust, Coolant loss with no visible leaks, Overheating after hard driving, Milky oil on dipstick or cap

Fix: Modified cars or those with boost leaks spike cylinder pressure, blowing the head gasket. Engine-out job in the Exige—plan 25-30 hours for removal, head work, and reinstall. Always pressure test the cooling system and check actual boost levels if buying a modified example. ARP studs and MLS gasket recommended for any forced induction rebuild.

Estimated cost: $4,000-6,500

Typical onset: 40,000-70,000 mi

Symptoms: Clutch pedal goes to floor with no resistance, Impossible to select gears, Fluid leak visible in bell housing area

Fix: The internal slave cylinder fails, requiring gearbox removal—12-15 hours in the mid-engine config. Always replace the clutch while you're in there since labor is 90% of the cost. Budget for clutch, slave, and throwout bearing as a package.

Estimated cost: $2,200-3,500