Symptoms
None at first, which is the point. BigJimny's wiki says every Jimny generation has 'particularly poor rust prevention' from the factory. The usual spots are the body and suspension mounting points on the chassis, factory welds on the chassis and axles, the boot floor, under the rear seats, the inner wheel arches and behind the side cladding.
The fix, step by step
- Wash the underside thoroughly and let it dry.
- Inspect the body and coil-spring mounts and the chassis welds.
- BigJimny warns that any existing rust must be removed completely before coating, because rust sealed under a coating keeps spreading out of sight.
- Treat cleaned spots with a rust converter and primer.
- Then spray cavity wax inside the chassis rails and body cavities, and an underbody wax over the visible underside.
- Keep the drain holes clear, and recheck every year, especially after salted roads.
Tools & part numbers
- Pressure washer
- wire brushes
- jack stands
- cavity-wax wand with a long probe
- protective gear.
Where to buy the parts
Hunting a used or discontinued part? Search eBay Motors for Suzuki Jimny JB74 / JB64 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.