Gearbox bearings - repair costs - an update

I finally got my Jimny back yesterday, after more than a month at the garage.

The Suzuki dealer took out the gearbox and couriered it to a transmission specialist, then put it back in and tested it. That cost me £240.

The transmission place stripped the gearbox and replaced a set of bearings, then sent it back to the dealer. That cost me £340

Total cost to me nearly £600

The transmission place had another Jimny in with exactly the same problem last month. So it seems it's quite a common fault. Mine is on 05 reg with 40k miles.

Did your gearbox had any signs of oil leaking ? I've read lots of posts regarding a faulty gearbox oil seal (from the factory), which is quite tricky to properly replace.

No, I've never seen any oil leaks, and neither garage mentioned any oil problems. The bearings went very suddenly, not over time.

Our 2006 VVT Jimny gearbox bearing totally disintegrated causing the gears to jump and mash teeth. Cost AU$2200 to repair with genuine parts. Was leaking oil afterwards, when I took it back for fixing the gearbox guy showed me how to replace the main input seal, the entire gearbox needs to be split. Pre-VVT has a 4 bolt plate to access it.

Pic of the main input on VVT Jimny, note there are no bolts around it.

Just had a similar problem on my 2008 Jimny 1.3 JLX+ Auto. Dealer says it is a "known" problem but not a recall issue. Symptoms were a slight whining noise when accelerating up a gradient at about 35-40mph. They had the gearbox out and "replaced the gear transfer". They removed and stripped the transfer box fitted new gears and rebuilt it. Fortunately, it was in the last month of warranty so I didn't have to pay for it. I gather it is about £250 parts and £400-£500 labour if you have to pay for it. Also had to pay for new front disks and pads at only 9,000 miles which was not covered under the warranty as Suzuki says it was "fair wear and tear". I hope the disks last longer than 9k this time!

Has any one done a guide on bearing and seal replacement on R72 gearbox?

I have not done a guide as I found it easier to get a specialist to do it.

I bought the parts and then they fitted them. They have a fixed £360 labour charge

www.bigjimny.com/index.php/forum?view=to...d=58347&limitstart=0

Martin

Excuse my lack of knowledge here, but what is the R72 gearbox out of?
My rocket is a 2010 Jimny, and I am looking at bearings, seals and synchros before it falls apart.
Roy

Well my "new" 2010 Jimny has the R72 gearbox, it's on the housing. Same as Zukenutter with non-removable bell housing and no access to the front seal unless you strip the gearbox. :huh: I decided to put a kit in as it was a bit noisy, it was leaking oil out the rear, and I could not get the filler plug out. Neither could the local garage!
Bit of a task removing it on my own, and even more fun getting it back in on my pat Malone! One bolt had damaged thread (hardest to get at of course) and needed rattle gun to remove it with lonnnng bars and socket. Lucky I had a spare bolt and tap to clean the thread in the block.
I got a specialist to rebuild it too. He stripped it in front of me and made it look sooo simple. Explained the 5th gear is direct drive through the main-shafts and 4th etc are via layshaft.
Kit with bearings and seals cost me A$220 from the UK, with postage and it was fast delivery. Had some genuine Zuke bearings included. Needed a second gear synchro ring as well, which I got from the local dealer. Could have bought all 6 on fleabay for the cost of the one from the dealer! Specialist cost A$430 including that expensive synchro ring.
Tail-shaft yoke was piddling oil out, lucky I saw a thread on it so suspected that issue, although this model should not have had this leak but there you go. Good clean up with brake cleaner and quality sealer fixed the problem. The frozen filler plug came out with big persuader (hammer) and long bar with 10mm square drive hammered in. Replaced with hex head brass plug so I can use a simple ratchet ring spanner in the very confined space (Note Mr Suzuki!!!!!!).
It's still a little noisy but at least I feel confident it will not go bang now (I hope). To me the gearbox is crap to use, slow and clunky, although I admit I'm used to the six speed M32 in my Astra, which while it has some faults, it is silky smooth and fast.

My '06 Jimny is harder to put in 2nd gear when downshifting, when upshifting it is harder than other gears but not hard. Other than that it works fine, no oil leaks, no noise, no vibration. Should I do something about the 2nd gear or just drive it like it is for now?