[Scott_1988]

Hi everyone,

I've recently joined the zook craze and purchased a 1999 stock auto Jimny, 150,000 on the clock. It's all roadworthied and I am driving it around but it does have some work needed to get it up to scratch for me. I want to do as much of the work I can myself but I am not that mechanically minded so I am not sure how big a job some of the things would be, so I am after some advice on each job and whether it can be done at home or needs to be done by a specialist.

What I want / need to get done is:

1. Timing belt replacement - the current timing belt is loose and knocks against the plastic guard around it causing a semi-loud knocking noise. A local mechanic quoted $590 to replace the belt and tensioner, said they shouldn't just retension the existing belt.
2. Transmission rebuild - the trans is worn out, I had a trans service due to the bottom pan leaking but it is just getting old. It clunks into gear, forward or reverse, gear changes are a bit rough etc....its old.
3. Rebuild front diff - there is a whining sound coming from the front (just assuming its the diff).
4. Rebuild back diff
5. Rebuild transfer case

Could probably skip the last two for now as nothing seems to be wrong them but I just want everything to be in good shape if I am heading out into the bush somewhere. The last thing I want is get stuck.

So is each job above achievable at home? Any specialist tools needed?

The car only cost me $3k so to pay a mechanic a lot of money to fix something that I could potentially fix myself doesn't make sense unless I can't do it myself, then I have no choice.

Thanks, Scott

[Gwagensteve]

Timing belt replacement isn't all that hard if you don't move the two pullies relative to each other. If you do, you need to retime the engine and that seems to stump everyone. How do you know it's the belt knocking against the cover and not some other noise? It would be pretty hard for the belt to be that loose.

Trans rebuild: This is a nope. Auto trans rebuilds require specialised tools and equipment. Parts are hard to get (basically just Suzuki genuine) and expensive. Best option here is finding a trans from a wrecked car. Expect to pay around $600 for a take out trans, or about four times that for a rebuild.

If there is a whining sound from the front with the car in 2WD on the road it's not coming from the front diff. If it's doing it in 4WD low range then it might just be the transfer case. Most front diffs on Jimny's are rusty from lack of use, certainly not worn out from use. Id be surprised. In any case, you'll need a selection of tools - dial gauge, torque wrench, special tools for the side bearing retainer tension, and a crush sleeve, along with bearings. These diffs can be very fiddly to set up (as in to get the correct preload and pattern) It's a job I'm happy to farm out if it's on a diff that's worth money/hard to get.

I'd leave anything else that doesn't require attention alone for now.

Steve.

[Scott_1988]

Hi Steve,

Thanks for the reply.

Gwagensteve wrote:

Timing belt replacement isn't all that hard if you don't move the two pullies relative to each other. If you do, you need to retime the engine and that seems to stump everyone. How do you know it's the belt knocking against the cover and not some other noise? It would be pretty hard for the belt to be that loose.

I am going on what the mechanic told me on this one. Can I pull the plastic cover off to see if it's loose?

Gwagensteve wrote:

Trans rebuild: This is a nope. Auto trans rebuilds require specialised tools and equipment. Parts are hard to get (basically just Suzuki genuine) and expensive. Best option here is finding a trans from a wrecked car. Expect to pay around $600 for a take out trans, or about four times that for a rebuild.

Ok, I'll leave it for now and keep an eye out for a wrecked one.

Gwagensteve wrote:

If there is a whining sound from the front with the car in 2WD on the road it's not coming from the front diff. If it's doing it in 4WD low range then it might just be the transfer case. Most front diffs on Jimny's are rusty from lack of use, certainly not worn out from use. Id be surprised. In any case, you'll need a selection of tools - dial gauge, torque wrench, special tools for the side bearing retainer tension, and a crush sleeve, along with bearings. These diffs can be very fiddly to set up (as in to get the correct preload and pattern) It's a job I'm happy to farm out if it's on a diff that's worth money/hard to get.

Whining is coming from front in 2wd...sorry, should have mentioned that.

[Sookie]

i have transfer case if you end up needing one $50 ararat vic

[Gwagensteve]

Yes you can pull the plastic cover, but from memory by the time you've done that you might as well change the belt and tensioner.

[Mike57]

Do you have vacuum hubs on that model. Front end noise in 2WD could mean one of your hubs is not disengaging.

[Gwagensteve]

That's a good point.

[Scott_1988]

Mike57 wrote:

Do you have vacuum hubs on that model. Front end noise in 2WD could mean one of your hubs is not disengaging.

Hi Mike,

I believe it does have vacuum hubs.

You are on to something here, when going from 2wd to 4wd and back while stopped, I can hear one side clicking in and out quite loudly but not the other side. I will check out the vacuum tubes and see what is happening

Thanks, Scott

[Rhinoman]

The timing belt is reasonably straightforward to replace. If you mark the old belt and the pulleys with some paint or correction fluid then you can transfer the marks to the new belt and you will be able to see that it is all lined up as before.