[danzook]

Hey guys, New to Auszookers and this is my first post/question.

I have just bought a Jimny and it needs a gearbox rebuild/new clutch.
I am doing all the work myself, hoping to start on it this weekend pending a few parts.
I can't for the life of me find out whether or not Jimny clutches are all the same. I have a 2009 with a m13a vvt motor but cannot find a standard suzuki or standard exedy clutch with pressure plate and bearing and also a clutch aligning tool.

So my questions are, is there a standard (non heavy duty) exedy or suzuki clutch I can buy with pressure plate, bearing and clutch aligning tool? Also is there any tips or tricks that might help me along the way rebuilding the gearbox and replacing the clutch?

I have got a 20 tonne shop press, a bearing kit for the gearbox, a bearing puller kit, a gear puller kit and many sockets, screwdrivers, spanners, hammers etc. I bought a rear main seal too as I will do that while I am there.

Cheers
Danzook

[ozzycouch]

Straight from the exedy web site http://www.exedy.com.au/clutch-finder
SZK-7245 has all the bits you are chasing for the clutch.
If you jump on an have a look there are options for standard or up rated.

As for the gearbox, sounds like your well covered to have a go at DIY - just do lots of reading and have a spare mode of transport available when it takes 10x longer than expected.

[danzook]

ozzycouch wrote:

Straight from the exedy web site http://www.exedy.com.au/clutch-finder
SZK-7245 has all the bits you are chasing for the clutch.
If you jump on an have a look there are options for standard or up rated.

As for the gearbox, sounds like your well covered to have a go at DIY - just do lots of reading and have a spare mode of transport available when it takes 10x longer than expected.

Thanks! that is awesome. I can't find anyone that sells the spigot bearing in Australia and also the alignment tool? I thought it would be much easier to buy consumable items like this.

[Dan`]

have you done a gearbox before? they can be a little tricky the few ive had apart. if there is a manual around for it make sure you have that handy. always make sure you know exactly which order everything goes, and work somewhere where the inevitable spring or ball that will go flying ends up somewhere that you will find it again....

trick that works in some cars is to drop one side rubber engine mount out and assuming the metal engine mount sits on the chassis part of the mount it can help give you just enough room to get the bell housing past the firewall if its otherwise really tight (never worked on a jimny so no experience if this is even needed tho, so take it how you like)

[danzook]

Thanks Dan,

From what I can see, it doesn't seem to be that tight but I will keep your trick in mind. I will take 100s of photos as I go so I can remember how things go and have the workshop manual on my pc, my phone and also print outs of the gearbox section. Pretty keen to give it a go. If I pay to have a 2nd hand gearbox fitted it could cost me up to $2k and the 2nd handy could have the same issues. I look at it as being cheaper to have a go myself. I have plenty of tools available and plenty of info recently digested haha. The rebuild kit was only around $300, clutch kit is about $200 and I am currently trying to find someone who stocks the spigot bearing and clutch alignment tool for it.

Cheers
Danzook

[greenzook89]

Another point to be aware of is the gearbox bolts can be extremely tight on Jimnys that are a few years old. I think zukenutter may have mentioned it in his build thread but cant really recall whereabouts.

[cairns27]

You should be able to eye the pressure plate in, but you can make a tool with a bit of dowell and a wood rasp, square the dowell, and just keep turning it and knocking the corners off...

bye

[ozzycouch]

danzook wrote:

I can't find anyone that sells the spigot bearing in Australia and also the alignment tool?

Same Web site, right under the clutch kit mentioned above

Clutch Alignment Tool - DCT-47
Spigot Bearing - 6002LLU

[cairns27]

The fitter here bough a Hi-lux clutch the other day, and it came with a plastic tool....

bye

[danzook]

Thanks for the help guys, you can't buy the parts from the exedy website from what I could see you had to locate one of their distributors. I did find a guy on ebay who sourced the parts and created a private listing on his shop so I could buy them. $20 for the tool and bearing delivered.

[ozzycouch]

Sorted, now you should start a build thread so we can see the progress.

[danzook]

Yeah I do have big plans for this zook. As soon as I have this gearbox sorted I will start throwing $$ at it

[Mike57]

May I ask what the issues are with your manual transmission. Mine is a 2009 with 40,000 km and it is now a little noisy. Interested to know what your problem is.

[danzook]

my issues are grinding and whining noises throughout different gears. Some sounds change as the clutch is pressed/depressed also. Have currently got the box out, hoping to pull it apart this weekend. The clutch disc has some odd wear on it as in the ends of the springs have been ground and the springs have a lot of play in them, seems the clutch may have been in back to front