Symptoms
Flaking scale on the frame rails and crossmembers, and rust around the body mounts and spring hangers. Classic Trader's LJ 80 guide calls rust 'a defining drawback', 'especially affecting the steel body panels and chassis', and tells buyers to check the sills, floor panels and frame.
The fix, step by step
- Wash the underside and scrape off old underseal so you can see the metal.
- Tap and probe the rails, crossmembers, spring hangers and body-mount points.
- Anything holed or thin around a mount needs welding by someone who knows frames.
- On sound metal, wire-brush back to clean steel, then zinc-prime and paint.
- Finish with an underbody wax, including inside the rails where you can reach.
- Free seized body-mount bolts with penetrating oil and replace any that are corroded while you're under there.
Tools & part numbers
- Scraper and wire brushes
- angle grinder
- pick
- jack stands
- spray gun or aerosol cans
- penetrating oil.
Where to buy the parts
Hunting a used or discontinued part? Search eBay Motors for Suzuki Jimny LJ series 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.