Re:Re:Is my 2011 Jimny gearbox dying?

I've been using the Jimny daily for the last month really. 

Generally fine but in the last few weeks almost imperceptibly, 3rd and 4th are getting noisier, along with 2nd and 1st, 5th is still quiet enough, I'd kinda convinced myself that it's always been this noisy but I've started doubting myself now. Noisier in gear when off the throttle but in gear, worst in 4th. 

Now I've got a new sound which is almost like this cyclical rhythmic noise, increasing with engine speed when in gear, again worst in 3rd/4th but present in other gears too. 

I'm guessing this is the gearbox dying. I thought that the R72 was modified in 2009 with better seals to improve reliability. 

It's a 2011 m13a with 99,000 miles. It had new fluid in the transfer box, gearbox and diffs 10,000 miles ago. 

What's the cost for a refurbished box and fitting? I take it, it's close to a grand? 
​I've attached a video of the noise, generally 2nd and 3rd gear pottering about the place below 30. 

Its so difficult to tell from a phone recording, they can make everything sound metallic as standard.
Yes the potential issue was fixed from 2009 with a sealed bearing in place of an open type. 
I believe its failure is usually accompanied with the inability to select gears, but I am not 100% certain.
Rebuild kits for DIY are about £130, expect higher if you want genuine Suzuki parts. Fitted recon boxes are about £1100, I guess you can pay more or less, but you are not getting much change from £1000. 
Secondhand boxes are about (£500 ish), but how do you know what you will get unless you find one from a low miles late build Jimny.
Me - I would drain the oil and look for bits. If it's clean carry on until something happens or look at other transmission parts. Axle and transfer box are all possible sources for strange noises.
Good luckMike

Thanks Martin.

That's my fear. I've parked it up for the while until I can reassess.

I'm going to change the gearbox oil for what it's worth and see if there's any metal bits. Otherwise it's really keep an eye out for a reconditioned box at a reasonable price. They really are rather expensive.

Would it need to n,

So I had got a dealer to change the oil the last time in the gearbox. It was only £60 at the time for the transfer box and gearbox and considering it's about half that in oil bottles from the local motor factor I didn't think it bad value. Plus, I couldn't get the fill plug off the last time so I farmed it out.

However, today I got the fill plug off without much bother.
The drain plug had some swarf on it, not sure if this is excessive as it was only changed 10k miles ago. But no chunks. So that's a relief.

More the the manuals specced fluid came out. I thought it was 1.1l but about 1.3 came out. I suppose they filled it until it spilled out the fill plug.

 

For 10,000 miles, I would class that as excessive swarf. I suggest you clean off the swarf, refill the box and be ready to do it again in 5,000 miles, or sooner if noise worsens.

Filling a g/box, T/box or either axle requires the car to be level, side to side and back to front. If it's not, the level will not be right, and may be over or under filled.

Roger

Yea this isn't looking hopeful. The fluid was a dirty olive colour. I've pulled nicer looking fluid out of 25 year old gearboxes

Changed it with Comma 75w/90 GL4 this afternoon.

For about a mile after the transmission oil change, it was quieter but then it's back to what it was, if not worse again. Quite loud in 3rd/4th, sounding like something with a straight cut gearbox and a cyclical chattering noise that's only there in gear, particularly in 2nd/3rd/4th under acceleration and off throttle in gear.

I think this box is beyond it now to be honest. I'm afraid of loosing the gears on the motorway or something.

Just a bump, if anyone knows of a decent specialist to look at this in West Yorkshire or North Manchester that would be great.

I am with Roger on this, that's a lot of debris on the magnet for 10K, that's assuming they cleaned it.
It also quite "chunky" which is unusual, normal wear and tear is a much finer grey paste stuck on the magnet, rather than shiny bits. The other ominous sign is the oil colour, when I have changed mine what came out looked the same colour as the new going in, and that was at 50k miles.
Not looking good at the moment, but check it again in a few miles as Roger said.