Suzuki Club UK

Hi All,

Got the replacement engine in, and how now fixed the carb problems i was having, so engine is running great.

I don't know if i mentioned that i dragged "Suzi" out of a barn, where she had been sleeping for the last seven years, but i am sad to report that i now have a gearbox noise, which is just soooo wrong.

Surely, it can't be me being used to normal road cars, therefore i have the following question - What is the gearbox supposed to sound like? i am guessing they are more noisy than say an astra, but mine sounds like two bits of metal hitting each other with no lube, is this a common problem? And when you put it in fifth at say 28mph, it gets noticeably more noisy, so bad in fact that i turned around and came home.

For information - i have a spare box which came with the replacement engine, which is noticeably quieter, no top end death rattle.

I am running in 2wd on tarmac, so in theory, i am guessing we are not talking transfer box? i checked the oil on this on sunday, and can report that it was full, and a nice golden colour.

Help,

Tim

The fact that it gets worse in 5th would indicate its the gearbox IMO, did you check that the gearbox had enough oil in? The filler is on the side, it needs to be filled up until the oil flows back out of the filler hole I.e. the oil is level with the bottom of the filler hole.

Obviously there is a bit more slack in the driveline of an SJ than a car as you have the backlash of the gearbox, tbox and diffs combined, not just the gearbox and 1 diff.

However I don't think it should be as bad as you describe? Remember though the transmisson is directly below you and not in the enginebay like a fwd car so you will hear a bit of a transmission whine.

It is a noisy car as a whole but what you're describing does not sound like the usual clatter you get from the drivetrain when you go from accelerating to decelerating and back again. To me that always sounded like the noise a door makes when you shut it.

Update - Ok Guys how about this. I have tonight checked the following;-

1. Transfer box oil level - its up to the inspection bolt hole, nice golden colour, smells and feels right
2. Diff - Oil as above, good. Nose bearing has been leaking, but level is good, colour good, etc
3. Jacked up the back end, rotated both wheels, observed the diff and driveshaft, all free moving, not a massive amount of backlash, brakes may be binding a little on drivers side, found a square nut on the top on the inside of the brake drum, and guess will adjust off a bit at the weekend when its light.
4. I have previously checked, over christmas, the oil in the front diff, and this was all good, the vehicle has only been driven to the end of the road and back following the christmas engine swap so i doubt it has leaked considerably since then.
5. Following the above, i consulted the Haynes manual, and it states that noises from the gearbox which are different in different gears, are usually a u/s box.

I have a spare gearbox which came with the second hand engine, true to the Guy who sold it to me's word, the engine is 100%, so would it be an idea to assume, as he told me that the box was also good, that i should now change the gearbox?

You thoughts?

If you are confident it is the box then it isnt exactly hard to swap over.

I say go for it

Dan

Thanks, i think this will be the cheapest option, although i have just received a curvy ball. I have been reading a thread on difflockhttp://forum.difflock.com/viewtopic.php?t=56634&postdays=0&postorder=asc&start=30" onclick="window.open(this.href);return false;

My gearbox noises are most pronounced in 4th and 5th, as per this thread, would suggest that its more likely a transfer box fault, and that it cost £400 to rebuild it, at a place in Reading, Berks.
GULP! This was supposed to be a cheap toy, balls!!!

Tim

Just change the gearbox for now and see. Not gunna take long and will only set you back the cost of some oil if it needs a top up.

Dan

£400 to rebuild the transfer box? Bloody hell, you could get another one for much less and a whole truck for that money.

Firstly it does not cost nowhere near 400 for a tbox rebuild. Pm rockwatt on here and see how much he'll do it for or buy the bits yourself and have a go, they are pretty simple. Bearings and gasket details can be found here http://www.suzukiclubuk.co.uk/phpBB3/ph ... t=bearings" onclick="window.open(this.href);return false;

Secondly I would agree if it only did it at high speeds then it would be the tbox, but you say its noisy in 5th at 28mph? What about 3rd at 28mph?

Have you checked the gearbox oil level?

Have you tried putting the tbox in neutral and then running through the gears?

Have you checked the tbox input and outputs for excessive play?

I don't think anyone ever came to an actual conclusion what the problem was in that thread, everyone could've had different problems, mine turned out to be the clutch release bearing.

ok

the noise is mostly present in 4th and a lot worse in 5th, i would not dare take it over about 35mph at present as it sounds like its going to go bang.

i have checked the gearbox oil level, this is fine

i have not tried your last point, putting tbox in neutral, and running thru the gears, what would this achieve, what am i looking for during this?

Thanks, Tim