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Loud rapid "clicking" or "burr" noise - gearbox ??

  • mlines
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17 Aug 2015 20:14 - 17 Aug 2015 20:15 #150004 by mlines
2005 VVT (yes - the dreaded year for gearbox issues)

Suddenly started making a noise in 3rd and 4th Gear only. (Going to work - fine, coming home - noisy)

Noise is like when we would put cardboard in the rear wheel of our pushbikes when kids to pretend it had an engine.

No noise in 1st, 2nd or 5th or reverse,

Only makes noise when moving.

No noise when clutch is depressed whilst driving.

Noise is the same in 2wd and 4wd.

Noise on acceleration and over-run, but by "balancing" the throttle when going from acceleration to over-run (i.e when no load on transmission at all) the noise goes.

Any ideas on the issue??

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses
Last edit: 17 Aug 2015 20:15 by mlines.

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  • zukiara
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17 Aug 2015 20:23 #150007 by zukiara
Mm 3rd-4th gear syncro bearing or collar spinning on the main-shaft :blink:

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17 Aug 2015 22:16 #150031 by facade
I agree, could be the splines on the mainshaft, or the centre of the synchro hub is split and opens up enough for the splines to go round. A selector fork problem that doesn't move the hub outer far enough to get the dog teeth fully into engagement would cause it to kick out of gear.


If it was the front countershaft bearing failed it wouldn't do it in 4th,as the drive doesn't go through the countershaft

The gearbox needs to come apart.

If it suddenly breaks, go back to the last thing that you did before it broke and start looking there :)
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18 Aug 2015 10:42 #150055 by mlines
Well as this is a daily drive we do not have the luxury of playing around with it in the garage.

Therefore I have booked it in with a local gearbox specialist for diagnosis and rebuild. They have fixed labour costs of £360 for the rebuild plus parts which seems competitive based on places like CAM-SUZUKI quoting close to £1000 for a used gearbox.

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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  • mlines
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18 Aug 2015 13:37 #150063 by mlines
£360 is the fixed labour charge, parts are extra!

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Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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18 Aug 2015 13:38 #150064 by mlines
That's for a removed box. £280 if they remove/re-install box

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Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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  • mlines
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18 Aug 2015 13:40 #150065 by mlines
New box is £1800+vat from suzuki

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Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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18 Aug 2015 13:59 #150067 by fozzie
£1800 is frightening!

I was lucky with mine as I'd only had the car 2 months before the noise started. I didn't buy the extra (insurance based) warrantee and had to play the 'not fit for purpose' excuse for the Suzuki dealer to repair it. Even then it was touch and go.

In my honest opinion, the way you are going certainly is the best. Good luck with the repair.

2012 Jimny Black. Totally standard (except for rear seat removal mod).

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  • mlines
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19 Aug 2015 08:42 #150143 by mlines
Well it just about made it to the Gearbox place this morning. Was getting worse and worse on the way, suspect we have a gearbox casing full of bits of bearings etc. :(

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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19 Aug 2015 16:51 #150185 by fozzie
Have you heard yet? Or haven't they started?

2012 Jimny Black. Totally standard (except for rear seat removal mod).

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  • mlines
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20 Aug 2015 18:58 #150257 by mlines
Well I phoned them at lunchtime for a progress report.

They said they would ring back.

After 90 minutes they did ring back and said "Its making a noise in 3rd and 4th" which is what I told them anyway,

So they have had it since 08:00 am yesterday and only drove it on a test drive this lunchtime when I phone up, NOT a very good start. Here's hoping they pull their fingers out!

P.S when my son drove it onto their forecourt I noticed a strange noise from the front, they said today that a front wheel bearing has collapsed. How is that for unlucky as it was fine the previous evening when I drove it to test the gearbox. Still I told them NOT to fix the bearing.

Martin

2003 M13 early KAP build.
3" Trailmaster lift with 1.5 Spacers on front
Customised winch bumper and roll cage
235/85R16 Maxxis Bighorns on 16" Rims, 4:1 Rocklobster, Rear ARB locker and on-board air
Corrected arms all-round, rear disks, Recaro seats and harnesses

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  • Daniel30
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20 Aug 2015 19:36 #150264 by Daniel30
I had a gearbox go on a Ford galaxy when I was getting it repaired I was chasing them all the time they seemed to be so relaxed about it?...... So frustrating so keep ringing them fir updates otherwise Monday they will tell you the same thing :angry:

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