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3rd Gen Suzuki Jimny VVT 2005 M13A - R72 Gearbox Refurbishment

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13 May 2019 07:53 #207839 by HUN
Hello All,

I've started populating some detailed (I mean very detailed) photos of the refurbishment of my spare R72 gearbox. I'm unsure if this Google sharing works or not. Please give it a try.

photos.app.goo.gl/2ftXQnt51fCvHoL59

Regards,

Gabor Stotzer

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards
The following user(s) said Thank You: Lambert, yakuza, florinelu07, Max Headroom

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13 May 2019 08:26 #207843 by florinelu07

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  • The quickest Jimny in Harrogate...(that I own)
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13 May 2019 08:42 #207846 by Lambert
Thank you for sharing!

Dreadnaught (black 2011)

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22 May 2019 16:23 #208685 by Max Headroom
SUPERB!

Thank you!


IF IT AINT BROKE, KEEP FIXING IT UNTIL IT IS

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26 May 2019 22:27 - 26 May 2019 22:27 #209041 by HUN
Thanks Guys.

Well, I've just finished the disassembly of the R72 gearbox today. I don't have too much time to work on this, but who has nowadays? Anyway.... at this moment it's alteady documented with 200 photos...

I think it's so detailed that it can be used by anyone without any explanation (you just need to feel confident to open the gearbox housing). Photos are self explanatory. Might be useful for those who does not speak English as there is nothing to read there! Ha-ha.

Now I had to realize that I have not ordered everything yet for this rebuild. Synchro sleevies needs to be ordered before I can carry on with this. Once I got them another few hundred photos will follow showing the assembly.
I hope it helps keeping your pride and joy on the road whilst you might learn something new like I did!
Enjoy.

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards
Last edit: 26 May 2019 22:27 by HUN.

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26 Sep 2019 20:53 #213890 by HUN
Hi guys.
After a month of waiting for parts I've nearly finished my gearbox rebuild last weekend. Unfortunately, I could not put back the rear section (3rd smallest part of the housing) of my R72 gearbox because the counter shaft bearing and the output shaft bearing do not line up perfectly. Possibly it's a very tight and precise fit. Managed to get those bearings half way pushed into place by pushing the housing down but then it does not go further. Does anyone had similar problem during assembly? Shall I try to heat up the 3rd piece before I give it a go? It's a real pain in the bottom especially because once the sealant is applied then there isn't too much time for messing with housing. Thanks. .

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards
Attachments:

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27 Sep 2019 08:18 #213912 by Dano0404
I don't remember having any trouble on mine with this. How ever that is a sealed bearing and I belive there is a seal on the output shaft so it could be trapped air? We have this problem at work with a lip seal against a sealed bearing, you can ease a small screw driver under to realise the pressure. It should be a tap fit a gentle tap.

Heating up can be a good idea but you have limited time to work with it. Also the risk of it going cold and not being where you want it.

Good luck
The following user(s) said Thank You: HUN

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27 Sep 2019 21:38 #213947 by HUN
Dano0404

Ahaa! So that's why it bounces back! I found this bouncing issue with the counter shaft bearing only which sits into the housing without let the air escape. I just have not realized that this is the source of problem. I'll give it a go then! Thanks for pointing me to right direction!

G.

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards

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28 Sep 2019 13:07 - 28 Sep 2019 19:06 #213969 by HUN
Sorted! Heating up with heat gun did the trick! :woohoo:
Ready!

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards
Attachments:
Last edit: 28 Sep 2019 19:06 by HUN.

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28 Sep 2019 22:57 #213982 by Daniel30

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29 Sep 2019 12:13 #213995 by HUN
Thanks Danny

Made in Japan. Type 5 model.
TrailMaster 2" suspension lift kit
Flo-Flex castor corrected polybushes
Kumho KL71 tyres
AVM manual hubs
Jimnybits all types of guards
Defender 1 steering damper
Pumpkin 6.2" Android & TomTom Go
MAD Individual seat cover
ORA radius arm chassiss mount guards

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29 Sep 2019 17:38 #214017 by Dano0404
Top work. Before I took mine apart it had a rattle in 3rd even though all the bearings felt good after I put it back together all was sorted. Have you tried running through the gears before putting it back in? I got something backwards in mine on my first attempt and could select all of them.

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