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Discussion Starter #1
The transfer of the gear in my 2002 Jimny is not soft, after changing the clutch and clutch cable the transfer is much better but the problem was not solved.
The main problem is transferring to the second gear after few hours of parking.
Any suggestions?

Thanks
 

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The transfer of the gear in my 2002 Jimny is not soft, after changing the clutch and clutch cable the transfer is much better but the problem was not solved.
The main problem is transferring to the second gear after few hours of parking.
Any suggestions?

Thanks
Did you change the throw-out bearing at the same time? Did you notice a rough surface on the input shaft when changing out the throw-out bearing?

Both of these things can cause a rough pedal.
 

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Discussion Starter #3
Jimny gear

Did you change the throw-out bearing at the same time? Did you notice a rough surface on the input shaft when changing out the throw-out bearing?

Both of these things can cause a rough pedal.
The problem is not rough pedal but hard gear engagement,
I changed the throw-out bearing and the input shaft surface is OK.
It seems to me that something is broken in the gear.
 

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The problem is not rough pedal but hard gear engagement,
I changed the throw-out bearing and the input shaft surface is OK.
It seems to me that something is broken in the gear.
Ok, so the problem is shifting it into gear.
1- Is it grinding as you try to shift? Does it feel as if the pedal is not dissengaging the clutch all the way?
-pedal tension needs to be adjusted

2- Or does it feel like the the pedal has made it all the way through its arc (completely dissengaging the clutch) but you still feel grinding at the stick?
-the synchro in the trans may be worn out at the 2nd gear.

If this trans has never been rebuilt, it may be time to consider it. If you do, get the kit with the synchros and swap it all out. It ony takes an afternoon, a clear work table, some hand tools and a decent set of gear pullers.
Here is something I put together to show how to do it.
Tranny Rebuild
 

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what type of gear lube are you running? you may be able to put off the rebuild by using a synthetic gear lube or synchomesh addative.. this wont fix you're problem but it will buy some time.
 

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Thanks PP.
On the synthetic, make sure to watch for leaks as a synthetic will seep past an old (hardened) seal. I use Amsoil extreme gear in both of mine, but that change happened after a total rebuild. At the price of the Amsoil, you don't want it leaving through a leak.
 

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Discussion Starter #8
Its looks like the synchro

Ok, so the problem is shifting it into gear.
1- Is it grinding as you try to shift? Does it feel as if the pedal is not dissengaging the clutch all the way?
-pedal tension needs to be adjusted

2- Or does it feel like the the pedal has made it all the way through its arc (completely dissengaging the clutch) but you still feel grinding at the stick?
-the synchro in the trans may be worn out at the 2nd gear.

If this trans has never been rebuilt, it may be time to consider it. If you do, get the kit with the synchros and swap it all out. It ony takes an afternoon, a clear work table, some hand tools and a decent set of gear pullers.
Here is something I put together to show how to do it.
Tranny Rebuild
Thanks for the guide, its fantastic, looks like the sychro should be changed.
Is the Samurai and Jimny gears are identical?

Erez
 

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Discussion Starter #9
what type of gear lube are you running? you may be able to put off the rebuild by using a synthetic gear lube or synchomesh addative.. this wont fix you're problem but it will buy some time.
I am using the one that recommended by Suzuki, its 80W-90.
Which synthetic oil from which company can you recommend?

Erez
 

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I am using the one that recommended by Suzuki, its 80W-90.
Which synthetic oil from which company can you recommend?

Erez
amsoil is probably the the best but expensive. you can use any 75/90 synthetic.. quakerstate etc.. or gm sells a sychromesh addative, i haven't been able to find it at local parts stores, but it works really well..
 

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Thanks for the guide, its fantastic, looks like the sychro should be changed.
Is the Samurai and Jimny gears are identical?

Erez
Thanks.
I don't know if they are identical, I have only worked on the US models. But before I had the service manual, I treated the tranny like a puzzle and just put it back together the same way i took it apart. you can try the same. If you wait more than a day to put it back together though, I would take notes...
 

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amsoil is probably the the best but expensive. you can use any 75/90 synthetic.. quakerstate etc.. or gm sells a sychromesh addative, i haven't been able to find it at local parts stores, but it works really well..
Good answer. Run the best you can afford/find. I got lucky and won some Amsoil product through a raffle, and until that runs out I will keep using it.
 

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Thanks.
I don't know if they are identical, I have only worked on the US models. But before I had the service manual, I treated the tranny like a puzzle and just put it back together the same way i took it apart. you can try the same. If you wait more than a day to put it back together though, I would take notes...

I have found that using a digital camera is helpful and laying the parts out on a piece of cardboard and labelling them really helps, it takes a little longer but well worth it. I have even had my kids label zip lock bags for the different bolts and such.
 

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