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The dreaded 2005 gearbox issue!

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29 Nov 2018 09:00 #198333 by Harry N
Hi Guys
Looking for a bit of advice as to how best to proceed?
I have a 2005 Jimny which has only done 50,00 miles and hasn't been thrashed.
I've developed a "ticking" in 3rd and 4th gear which after a bit of research I've realised is a recognized fault.
I've taken it to the main dealer and they have offered to fit a new gearbox and change the clutch for the princely sum of £3500 which I would guess is more than the value of the car!
What to do? Having looked on this website I don't have the technical ability to sort this myself!
Keep driving the car and hope for the best?
Look for a reconditioned or second hand box and get my local garage to swop it?
Find a gearbox specialist and see if they can repair the fault?
Spend £3500 and put it down to bad luck? (I've had to spend very little on the car since I bought it in 2010 so I guess I can't complain too much...)
Any thoughts or advice gratefully received!

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29 Nov 2018 09:57 #198337 by facade
See if your local garage can remove the gearbox and fit a bearing kit then replace it.

If not, see if there is a specialist who will.

It is a fair amount of work getting the gearbox out, but replacing the bearings is easy, I'd have thought less than £1000 including the parts should do it, but I never pay anyone to do something I can do myself, so I don't have much of a handle on garage prices.

If it suddenly breaks, go back to the last thing that you did before it broke and start looking there :)

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29 Nov 2018 11:06 #198346 by Busta
The most economical course of action is definitely to get your box repaired, and sooner rather than later! You run the risk of damaging the box if you continue to use it. Reconditioned boxes are expensive, used boxes are hard to find and potentially have the same problem, and whatever route you go the cost for removal and refitting is unavoidable.
I'd look for a local gearbox specialist and speak to a few local independent mechanics. It's not a big job for people that work on cars and the good independent people normally charge more fairly than the garages full of less experienced 'technicians'.

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29 Nov 2018 11:23 - 29 Nov 2018 12:48 #198348 by Max Headroom
You could try draining and flushing the g'box and getting fresh oil into it to see if that helps but I think its a matter of time...
I drained mine and refilled it in March, and although I have no noises or problems yet, there was swarfe found on the mag-plug.

If thats the R72 gearbox, only a matter of weeks back I got a hypothetical quote for replacing the box on mine with MR Clutch . The Swindon branch changed my clutch a few weeks back for £250 which I thought wasn't bad as I neither have the time nor the facilities to undertake such a task

Obvioulsy you would probably want to consider doing a clutch cx at the same time while it's all apart




IF IT AINT BROKE, KEEP FIXING IT UNTIL IT IS
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Last edit: 29 Nov 2018 12:48 by Max Headroom.

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29 Nov 2018 12:21 #198350 by Daniel30
I was lucky enough to get a 2016 gearbox and fitted a new clutch at the same time all came to about £1100

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29 Nov 2018 12:23 #198351 by Daniel30
I wouldn't of entertained the dealer not at that price

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29 Nov 2018 12:43 #198354 by paradox1001
Find yourself an independent gearbox specialist and get them to quote you.
I bet it will be a lot cheaper than you’ve been quoted.

Is it specific years that have gearbox problems?

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29 Nov 2018 17:10 #198378 by mlines
around £700 from a specialist gearbox rebuilder in Berkshire, less if you put in some of the work yourself

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Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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29 Nov 2018 18:30 #198388 by Max Headroom
Martin, is that price (£700 ish) assuming that the gearbox is already removed?


IF IT AINT BROKE, KEEP FIXING IT UNTIL IT IS

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29 Nov 2018 18:39 #198389 by OlaGB

paradox1001 wrote: Find yourself an independent gearbox specialist and get them to quote you.
I bet it will be a lot cheaper than you’ve been quoted.

Is it specific years that have gearbox problems?


Not sure what year, but at some point they changed from open bearings, to sealed bearings. I rebuilt my own box, and got only sealed bearings in the kit i bought. The seller sold tons of gearbox bearing kits, and said the sealed bearings where more expensive, but last longer and is used by many manufacurers stock as well.
Yakuza (member here) bought a low km 2013(?) box used, and inspected it with a small cam and found sealed bearings in it as well..
The bearing that dies first, seems to be the highest rear one. Probably not enough oil flow around it, or maybe the most loaded bearing, not sure.

I´m only 8k km down the road after rebuilding, so its too early to say anything about lifespan.
The following user(s) said Thank You: paradox1001

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29 Nov 2018 19:09 #198390 by yakuza

OlaGB wrote:

paradox1001 wrote: Find yourself an independent gearbox specialist and get them to quote you.
I bet it will be a lot cheaper than you’ve been quoted.

Is it specific years that have gearbox problems?


Not sure what year, but at some point they changed from open bearings, to sealed bearings. I rebuilt my own box, and got only sealed bearings in the kit i bought. The seller sold tons of gearbox bearing kits, and said the sealed bearings where more expensive, but last longer and is used by many manufacurers stock as well.
Yakuza (member here) bought a low km 2013(?) box used, and inspected it with a small cam and found sealed bearings in it as well..
The bearing that dies first, seems to be the highest rear one. Probably not enough oil flow around it, or maybe the most loaded bearing, not sure.

I´m only 8k km down the road after rebuilding, so its too early to say anything about lifespan.


I think mine was 2012 or 2013.. A bit hard to say with nowegian jimnys, but i think i kept the vin somewhere.
I read somewhere that after 2009 there is an upgrade.
I am abusing mine now with m16a engine, but i think the low gears in the transfer box helps putting more of the torque over to that box.

I top up my gearbox oil every so often now as i got the leaky intermediate shaft as well. Could have been a factor with my old gearbox failing, not sure..
I got these sounds from the bearings in the box, and when they got a bit worse, the box had a total inner failure after 15-20km. If you have noises from the bearings just stop driving and get it fixed.

2005 Jimny M16A VVT, 235 BFG MT, 2" Trailmaster, 17%/87% high/low gears.
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29 Nov 2018 19:23 #198393 by paradox1001
Ahh mines a 2002 so could possibly be one of the boxes that have problems.
Might be an idea for me to change the oil as a precaution

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