Symptoms
Grinding or whining when cruising in 3rd or 4th on 2005-ish to 2008 petrol trucks, and a furry drain plug or metal chunks in the oil.
The fix, step by step
- Remove the gearbox, split the three-piece case and replace the open deep-groove bearings with metal-shielded ones, as Suzuki's later parts do.
- BigJimny suspects early oil starvation (some trucks also had leaking prop-shaft center caps).
- Keep the synchro rings, clips and needle bearings in order.
- The procedure is in Suzuki supplementary manual 99501-81A10-01E.
- Do the clutch while the box is out.
Tools & part numbers
- Transmission jack
- bearing pullers
- impact sockets for pressing bearings
- liquid gasket.
Where to buy the parts
Gearbox Rear Oil SealBigJimny ↗Amazon ↗
Clutch Kit, Exedy Safari TuffBigJimny ↗Amazon ↗
Hunting a used or discontinued part? Search eBay Motors for Suzuki Jimny JB23 / JB43 parts →
Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.