Suzuki Jimny 'FULL' Breather Kit - Diff / Axle / Grarbox / Transfer Box Breathers

Suzuki Jimny 'FULL' Breather Kit - Diff / Axle / Grarbox / Transfer Box Breathers

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£39.95

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Product Information
Specification

Suzuki Jimny 'FULL' Breather Kit - Diff / Axle / Gearbox / Transfer Box Breathers

A  'FULL' kit to extend all* of your breathers to the highest point possible.

Kit Includes -

  • 8m of pf flexible nylon hose (8mm OD / 6m ID)
  • 1x 5-Way Manifold Block
  • 1x Blanking Plug (to block one port off if you wish to do the Transfer Box later)
  • 2x Self Tapping Screws to mount the manifold block to the engine firewall
  • 1x Drill Bit to match these Self Tapping Screws
  • 3x Threaded Elbows (to fit into the original breathers)
  • 1x Tap to match these elbows
  • 1x Drill Bit to match the Tap (for the Transfer Box Breather)
  • 20x Tie-Wraps

Fitting Instructions -

The 'Full' Breather Kit is a bit more awkward to fit thanks to the transfer box breather (but read on!).

The various components are all fed through separate nylon tube runs running to a manifold block, i.e. connected in parallel...

The complication with the transfer box is that you have to  drop it out from under your Jimny... this is the bit that will put a lot of people off... but it's worth the hassle if you're regularly playing in the mud or fording rivers and streams...
This is the one out of my buggy so ignore the super duty bracket/skid fitted to it, but you can see the breather at the end of that big yellow arrow wink


enlightenedThe kit includes a blanking plug for one of the manifold ports though, so that you can fit the transfer box breather at a later date, when you have scheduled maintenance work, or repairs to do, that mean draining and/or dropping the transfer box out...


 

We start though by tapping both the original axle breather tubes once the caps have been removed. (They simply pull off with some force and locking "mole-grip" pliers...

Take your time and slowly twist the tap into the existing breather tube keeping the tap straight, preferably using a good tap handle...

Then the threaded elbow can also be carefully threaded into the newly cut threads in the axle breather tube.

Starting with the back axle, insert the nylon tube into the threaded elbow, it's a push-fit connector so it just grabs the tube as you push it in yes

Then attach the tube to the axle tube (to the brake pipes), then up the offside radius arm, and along the chassis rail using the brake pipes again...
Don't overtighten the tie-wraps, you don't want to squash the nylon tube.

The nylon tube run can then go into the left port on the 5-port manifold block included in the kit, this is supplied with a small drill bit and two self-tapping screws to attach it to the engine firewall / bulkhead. All the other tube runs will then terminate at this block too - so the three ports pointing downwards will be the front axle, gearbox, and transfer box, and the right side port will head off to the highest point, more on that later...

So repeat the process for the front axle and run the tube up to the left port of the manifold block yes

Next the gearbox breather... this is is a couple of different places depending on the model...

Soft-Top

The gearbox breather on the soft-top models is quite easy to find but awkward to get to! laugh

If you lie on your back and shuffle under the Jimny from the passenger / nearside and look up into the transmission tunnel you'll spot this very simplistic breather... Yup, it's a plastic dust cap on the end of a short piece of rubber hose...

Squeeze your arm up and remove the cap and the supplied nylon tube will push snugly into this little breather hose...

Bit of a twat of a job, but with plenty of swearing you'll get there! laugh

Then run the breather tube back to the offside chassis rai and all the way up to the middle port of the manifold block.#

Hard-Top

The hard-top is a bit easier! laugh

Again, one of my Jimnys... laugh Here you can see the breather positions... Where I'm pointing is the same plastic breather cap on the end of a rubber hose like the soft-top but easier to get at... and in the next photo which is a closeup of the right-hand yellow ring...

There's the breather hose coming up from out of the top of the gearbox...

 So we simply remove the cap, push the nylon tube into the rubber hose, and then run the breather tube back to the offside chassis rail and you guessed it...

Into the middle port of the manifold block yeswink

Now then... the transfer box... As I said before, you can either put the blanking plug into the right hand port of the manifold block and leave this step for another day when you're doing something that requires the transfer box to be dropped, like fitting new HD mounts, or swapping a prop, etc.. Or, go for it now! laugh

First job then! Is to to drop the transfer box out from under your Jimny... this is the bit that will put a lot of people off... but it's worth the hassle if you're regularly playing in the mud or fording rivers and streams...
This is the one out of my buggy so ignore the super duty bracket/skid fitted to it, but you can see the breather at the end of that big yellow arrow wink

I'd leave the oil in for now... it's only an extra kilo to bench press out from under the Jimny laugh and will bring any swarf out with it at the end...

Ok... we start by prising off the spring loaded breather cap...

And then we first drill down through the breather tube with the supplied drill bit... that is the right size to prepare the breather for the tap that would have come with the Basic Breather Kit you've previously bought. Then we carefully run the tap into the widened breather tube...

This drilling and tapping will deposit some swarf into the transfer box... so before refitting it, give it a bit of a shake and then empty the oil out, ready for refilling when it's back under the Jimny... This is also advisable anyway if you've been offroad / wading without "proper" breathers wink

This will leave us with a nicely threaded hole... (Excuse the slightly blurred photo!)

Then we can carefully wind the breather threaded elbow in... yes

Then empty the oil. fit the breather tube into the elbow first (as it's a job to get it in once you've bench-pressed the transfer box back into place!) and then refit the box and refill with nice fresh oil. wink

Then run the breather tube back to the offside chassis rail and once again to the...

... bottom right port of the manifold block! smiley

One more port to go then?! The right hand upper port then needs to go to the highest point possible on your Jimny...

So either...

... into the snorkel head if fitted, this is my installation on a previous Vitara of mine ... 

And have the tube protruding into the head of the snorkel like this...

... or, ... again into the snorkel head if fitted, this is my installation on the Jimny-Buggy... These filters are listed in the breather section of the store if required.

If you don't have a snorkel fitted, these filters are also available in the breather section of this store with a neat little bracket to terminate the run of tube...

That should be it then!...

Hmmm, I've written it as a 'Full' Breather Kit, but ten we start discovering more vents to atmosphere... Take the charcoal canister filter for instance -

It has a vent on the bottom of it?! Here's a photo from the workshop manual..

So the store also features an optional Add-On kit to add a breather tube to this...

A T-piece to add next to the manifold block...

Some more nylon tube and a short length of silicon tube to connect to the breather vent on the underside...

 

 

Product CodeJIM-Ful-42B
ManufacturerZookBOB
ConditionNew
Weight0.752kg
Height3cm

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