jimny gearbox removal!

[petetong]

having to drop the box out of the jimny.. (having problems with the selctor?? 3rd and 5th playing up???)
its all ready to come out.. but! it won't drop down past the rear gearbox mount (the chassie one)??? now the box has been out before(finger tight nuts were a give away to start with ) as you can see were some one has had the same prolem as im haveing.. but thay have cut the rear mount in haft, then welded it back on!!!
i could do the same if i have to.. but i can't see that suzuki would have made it in such that the only way to change a box(or clutch for that!) would be engine and box out!!!!
so any one got any thoughts??

p.s. did think that if the engine would tilt ack just a tad more, the box might just clear the rear mount..but the crank sensor houseing hits the bulkhead before theres enough room so is it housing of for enough clearnce??

[scut44]

Sorry but never dropped a manuals gearbox.
Always had an auto out with the engine out.

Maybe some help to see whats there,
here is how it looks from above.
Surely someone here will know whats required.
all the best.
george

[mnl]

There is a guide on Bigjimny.com, for clutch changing.

Basically, you remove the remote selector and bracket, that shortens the gearbox enough to come out. The transfer box has to come out too.

(I've not tried, when its clutch time I think the engine comes out)

Edit: I've read it now, and the clutch has to come off as well

[mlines]

In some kind of joke the Suzuki Workshop manual warns you that the gearbox can drop on you when you have undone the bolts.

When I did mine (see guide on BigJimny) I could lie underneath the car with both arms wrapped around the gearbox and hang my weight from it and it would not come out!!


You basically have to undo everything, including removing the clutch plate through the gap, then the gearbox will drop. I also ratcheted the engine as far forward as it could go using a ratchet strap.

Martin

[petetong]

well i took the easy option(ish!!) and cut the mount off again..
so it pressure plate of to is it!! yeap can see that that might give JUST!enough room..not as easy as an sj box to drip then!
interestingly the problem turned out to be pinch bolt that holds the selctor rod in the selector houseing,had come loss and dropped down in side the housing! and then was in there moving around.. so would jam up from time to time.. and that is way some times you would get no 3rd.. or no 5th!! etc.....
some thing for other to thing about if thay have simler happening

[wee-arthur]

We did it twice on our Jimny, Took us about two and a half hours in all. Simple really big meccano.

Just pull the gear selector bracet off from the back and the gear linkages, all engine bolts and then there is one mounting point to undo. The reason we removed the rear bracket is so that you can slide the whole gearbox and transferbox back onto the crossmember.

This gives you enough room to remove the clutch and replace between the gearbox and the engine.

Note: there was two of us and i held the box while he put the clutch on... The gearbox is tricky to get a hold of but tbh if youve worked on a land rover its a box of matches to lift and shift back. We had a ramp the second time around but lying on our backs the first time while trying to see how to do it we did it in about 3 hours 30

Good times

[vitara_mad]

just done a clutch on a jimny for the first time it was quite simple realy did not have to take the trans box off either but we did not drop the box onto the floor just sided it back & rested it on the cross member as it would not drop out unless the selector & mount is unbolted first & did not see the point of unbolting it just to change the clutch

[petetong]

[mnl]