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1. Is there any agreement on here - is the Jimny auto weak?
The jimny auto is at the limit of its torque handling capacity behind a G13BB. (110Nm) This is unlike the vitara autos, which can handle far more torque than their sent by the vitara engines.
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2. I have 31's, have a WT TC that I want to put in but will be running 4.16 or 4.9 gears? (Can't remember which was suggested to me I need to look through my messages) and the Jimny auto would also further increase the low range reduction is that correct?
Sort of. 1st gear in the Jimny auto is 2.95 or thereabouts - its not lower than your manual. However, the torque converter can slip and when it does it acts as a gear reduction - the ratio is around 2:1, so when engine revs are below torque converter stall speed (circa 2000rpm) and load is high, you can get an equivalent 6:1 out of first gear. However, once revs rise above stall speed, you're back at whatever numerical gear ratio the gearbox offers. This is great for crawling, but slipping the converter generates LOADS of heat, and heat kills automatics.
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3. What kind of RPM could I expect to sit on for 90/km/hr or 100km/hr with this set up?
Cant help there. Search the ratios of the Jimny auto in 4th and compare that to your manual. It's likely cruise revs will drop a bit.
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3a. On this note am I correct that 5.16 gears would leave me sitting on 4000RPM at 80kim/hr or close to? However 5.16 gearing would give me better low range crawling ability right?
As above. You'll have to crunch those numbers for yourself. It's not hard to build a gearing calculator in excel - it's 10 minutes well spent.
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4. Is there another auto that is considered stronger then the Jimny (if it IS considered weak) that is a fairly easy swap? (no tunnel modification) eg Vitara? what would the gearing effect of this be on the above mentioned set up?
No auto will fit without tunnel mods. Every other auto is stronger. Trimatic from a carby vitara would be the easiest fit with a lucky 13 adapter but you might have issues with road gearing (or maybe not - don't jimny's have a direct 5th gear?) the AW-4 is probably the ultimate auto, but it's bulky and requires electronics to make it shift. It has very nice gearing though and is well suited to off road work. Any auto is going to require jackshaft and mount modifications, work to adapt a shifter, tunnel mods, some wiring, potentially a kick down (TV) cable install, cooler and gauge. It's not a small job. Tunnel mods are neither here or there.
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5. If there is not an easy option is there modifications that can be performed on the Jimny auto to help it out?
The first thing is to make sure you're not using the auto to correct for inadequate gearing. If the auto won't lock the converter on cruise and you're slipping the converter hard off the line it's going to die. Gearing needs to be spot on. Then, a really big cooler, or two, and a gauge. There's nothing else. These autos don't have any aftermarket support so there isn't a shift kit or upgraded clutches or anything for them.