Oil leak gearbox - 2001 Petrol manual

I have a new oil lean on my gearbox and wondered if anybody had seen same issue. We noticed a burning oil smell, on checking there was a stream of oil down the side of the gearbox ( about half way down), dropping onto the catalyst. Getting a mirror and it seems to be coming from a hole on the top, looks like a cross drilling for assembly of detents. Looking online for picture there should be a bung in there (see picture). I contacted Suzuki but there is no replacement part - going to try and block it off, what I can't figure out is why after 80k does it decided to fall out. Anybody seen similar issue? I did get the parts department to talk to the workshop and they said they had seen similar issue on Vitara and they just something to block the hole.

2 days before I noted a leak from front diff as well, could they be related? Had been running in 4wd the day before.

Was wondering about a blocked breather, I've got an external pipe that links all breathers to the same pipe and vents in the engine bay, been  fitted for a while and no issue, but going to check is clear. Blocked breather pipe, hard driving, hot oil building up pressure and pop?

Have new diff seal just in case, is it possible to change without replacing crush washer, just making up flanges, shafts, etc?

Any help greatly received..



Here's my gearbox. Easy to see with NSF wheel removed..
 

I decided to plug with a bolt and some JB weld. Hopefully it will hold until I can find a proper bung (did think about using a cork as well).
 

I have not heard of such a leak before. Your explanation with the pressure build up sound plausible.

The diff input seal can be changed from the outside without setting the diff up after, just to remove the flange and change the seal.
The flange however can be a challenge to get off there.
There is a large locking nut in the center of the flange with a sleeve formed/hammered into a recess in the shaft. Must be "opened" properly before attempting to loosen the nut.
It is not so difficult with a large pneumatic impact wrench.

Fairly common, and not just on Jimnys, I've had it happen on both first & second generation Vitara/Grand Vitaras.

Whoever told you there is no replacement part is either too lazy to look it up, or doesn't know what to look for - it's a rubber plug, P/N #09250-10006 - USD$1.68 from megazip in Japan. As far as I know, it's the same plug on all three models, it closes a drilling used to insert the interlock detent balls.

I would suggest you not JB weld a bolt in there, a rubber or plastic plug with a smear of RTV sealant is preferable, you might need to remove it at some point.

This in from the local Suzuki dealer, they contacted Suzuki and asked...

"Suzuki have come back to me on this for you and I'm afraid it's not good news. The part you are after isn't available as a separate part and only comes with the gearbox itself."

I'll lock at the bing you found, thanks for that.

Seems generally available in lots of outlets including some in the UK

Martin

In fact the plug is IN STOCK IN SUZUKI and would be £2.17 from me plus £2.20 postage (1 week lead time)