Gearbox removal

Has anyone removed the gearbox on their Jimny?

I want to know how easy it would be to do on my back at home! The clutch is on its way out and will need replacing very soon. I have access to a workshop with ramps but we are busy at work at the minute so I might have to do it at the weekend at home!

I've had a look and it doesnt look bad but my only concern is the chassis cross member. I'm not sure if the gearbox will slide past the cross member.

Anyway any help would be greatly appreciated!

Cheers

Chris

See my guide here....

www.bigjimny.com/images/documents/Changing_the_Clutch.pdf


The difficult part was getting the gearbox off. The Suzuki manual warns you that it could drop on you and cause serious injury when the bolts are undone, well with mine all undone I could hang onto the gearbox with both arms around it and it still would not shift.

A few people have managed to change the clutch without really taking the gearbox off, just by pulling it back and squeezing in the gap.

If you are taking the geabox off then now is the time to fit a breather pipe to it as it is impossible to do at any other time.

Martin

if you just want to change the clutch you should be able to unbolt the box & slide it back a little fit the clutch & slide it back on ive done it that way & also ive had the gearbox all the way off & on the floor on my bro's jimny by removing the gear selector of the back of the box first theres plenty of room then

what i did to my jimny was to cut the cross member off & make some brackets to make it a bolt on cross member so it was removeable

Bolt on cross member sounds like a real good idea. Pity it wasn't done from the factory.

I removed the transfer box and slid the gearbox back this morning on my back and it took a couple of hours. I only removed the transfer as its knackered and I'm swapping it. You can leave it on. I did take the gearbox lever and bracket off too to give me more room. Some of the bolts (engine to gearbox) were extremely tight and I didn't think they had been off in 11 years of use.

Just waiting for the new clutch to come now and then it can go back together.:laugh:

Cheers guys. I think I will remove it fully as I need to fit the breather pipe!

I have seen a Jimny for sale somewhere which said it had a removable cross member made by KAP. It said you could change the clutch in an hour instead of 3 hours. I've looked on their site and I cant find one. If I get chance I'll pop in and talk to them about it.

Chris

I had to change the gearbox and clutch on mine a few month ago took me bloody ages cos the how to guide on here is an older model and mines an 07 reg i managed to do it in the end and its. Ot hard to do if you do need to remove the box rotate it when removal and refitting all you need to take off other than that is the exhaust and disconnect prop from front axle altogether with me not knowing what the hell i was doing took me about 5 hours. Also if you do remove the box its easier to locate the clutch as you can get your head in the gap to align it perfectly without an alignment tool.