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My Jimny is currently off the road. A specialists transmissions garage has just repaired a Jimny with similar symptoms to mine, and charged the owner:
£280 (plus vat) for stripping the gearbox and replacing a broken bearing
£160 for removing and replacing gearbox
Total approx £500
Update: Mine is at a dealership garage, they have suggested buying a 2nd hand gearbox would be cheaper than trying to repair. There's a few on eBay about £300.
I had a similar problem recently. One damaged bearing but Gearbox specialist recommended, knowing what the car was getting used for offroading, replacing five bearings whilst the box was off and open. Total cost approx £220 I think. Removed and replaced gearbox with help of a friend. Three out of the five bearings could only be got from Suzuki. Keeping your own gearbox, you know exactly what youve got and how many miles its done.
I have a funny feeling that this is a known problem with some Jimnys. A long time ago there was discussion about this on another Jimny forum and the person got Suzuki to admit there was a problem and they replaced the gearbox.
Found it.....
Sorry for the delay on this but just got t'internets back after moving house.
UPDATE:
The gearbox was stripped, photos were taken and sent to Suzuki. Technical guru from Suzuki just happened to be walking past the next day?!? Took one look at it and said "Replace the whole gearbox! Send that one to head office for examination!"
Apparently a bearing collapsed sending little bearing bits all over the gearbox. Made a right mess. Technical guru sad he'd never heard of anything like it in the history of Jimny gearboxes. I'm so proud!
So, brand new gearbox under warranty, Suzuki assistance were fab with organizing the recovery and free hire car. Took over a week to get the car back but all in all, not bad.
THere were no other details but it was a guy from Scotland
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
mlines wrote: I have a funny feeling that this is a known problem with some Jimnys. A long time ago there was discussion about this on another Jimny forum and the person got Suzuki to admit there was a problem and they replaced the gearbox.
I'm intrigued. Where can I find out more, or how do I go about contacting Suzuki to ask about this? Mine is a 2005 model so there's no warranty or assistance anymore.
The rattling noise starting very suddenly, only in 1-2-3-4 gears, quiet in 5th. Then after about 100 miles driven on it's last trip to the garage was reluctant to change into 2nd with a loud clunk. So I suspect it may be a bearing on it's way out and then further damaged caused.
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