It is the second time within 40 days that my left axle shaft was unhooked! The result was gearbox lubricants leak and eventuality I lost instantly all gears while driving at high speed! As another owner reported me the same problem, I suggest you to check it ASAP for your own safety!

Whoa, that's not cool. Are there any early signs we should be looking for?

Substantially, no. There's no former warning for the driver. But a couple of weeks ago during the 15000 km regular service, the engineer found out that something was wrong with the axle shaft safety. We also detected oil spots on the floorboard, obviously from the first time the problem appeared. He replaced the safety and told me to drop by a few days later to check it again. I did and everything looked fine. But not for long.. Two days ago as I was cruising on the highway with 5th gear, suddenly the gearbox "passed away" after a slight kick! Just like the first time, less than 2 months ago!
Man, I'm pissed off and indignant! I'm thinking of sending e-mails to Suzuki and all the local car magazines mentioning I'm going to consult an attorney! Because it's the second time it happens in short time period! And who can guarantee it won't happen again? And if it happens again during an overtaking?

PS Please forgive the misuse of my poor english as I am resident of Greece.

READ THIS

I have had exactly the same problem(being fixed at the moment(factory warranty)) and some dealers have had the problem with other ignis sports aswell

The surclip that holds in the left drive shaft is prone to coming off, allowing the drive shaft to come out of it's mount.

Suzuki have realized the problem and there is a modified drive shaft and heavy duty surclip available to rectify the problem, they also have to change the spider gears, all up a lot of labour but much better than a blown gearbox.

Mine is being fixed under factory warranty, when you take your car in for a service, see if you can get them to check it out.

Cheers to the guys at for sorting my car out and doing it the proper way instead of putting in a new surclip

I just raised this exact problem with the Services Department Manager of Suzuki Australia (Rohan Costello) and asked if he was aware of the problem. He said he was aware of the issue, and that it had happened to 2 vehicles (I believe yours was one).

When I asked about what was being done, the discussion fairly rapidly fell apart. Apparently there are no specific Suzuki procedures to rectify or check the problem, and dealers aren't being made aware of it. Additionally I was not told what justified a recall and if Suzuki did have a replacement scheme for this problem (they apparently don't believe it is justified.. so I am not sure how you are getting yours replaced with different items?).

At the same time I asked about formal procedures about the 'hood fly up' bulletin that was released in the US (this is extremely relevant because of the number of cars that have the issue in Australia). He was apparently unaware of any vehicles having this problem in Australia, and there is also no procedure or bulletin released for this problem in Australia.

I am personally concerned about this problem, and their apparent lack of concern about the problem has me a little put off. This is starting to sound a lot like the vehicle recall quote from Fight Club.

-edit-

If _anyone_ else is aware of any instances of this of anything like this happening, PM me ASAP

In case anyone from Suzuki reads this, we were made aware of the problems by owners of vehicles, not dealers.

There are at least 3 cars in WA that have had this problem, get the dealer that you are talking to, to check the part number of the drive shaft for the ignis sport, they should notice that the part is now discontinued and that a modified part is avalable in it's place.

Yep, I need to organise a time to talk to you about this, PM me when you get the chance etc. Cheers for the info.

Well 2 days of solid searching and I have found two more UK owners who have had the exact same problem.

I have also chased up some invaluable information. Suzuki Australia claimed to me there wasn't any bulletin etc about the change, but then I found out this little bit of information.

The inner circlip on the left hand side drive shaft in the Ignis Sport is superseded
The original part number is: 09381-24001
The supersede part number (newer circlip) is: 44111-65D00

I still need to confirm these part numbers are exact (I am 99%), but there is definitely a supersede issued by Suzuki for the circlip. I was unable to get any information about a supersede on the driveshaft however, but I believe there is one.

So if this happens to you, Suzuki know about it.. and it seems Suzuki Australia would prefer you didn't, the labor estimate to fix the problem is astronomical.

Hey all, hope this helps, copy of part of my original post from sisoc.co.uk, which is in it's infancy. May not be relevant info in Oz, but problem is exactly the same.

Quote:

OK, the biggy, DRIVESHAFT: Guy I bought my car from works as a Suzuki bike mechanic, and had access to Suzuki databases etc until recently. He had the driveshaft problem, at normal driving speed, on way to work. Looked on database and there is an issue with a batch of Ignis, mine included in this batch.

Suzuki had the car for 2 days; job entails gearbox out and stripped, a modified planet gear fitted (the gear in the diff that the driveshaft engages with), then they supplied new shaft, seals, c rings etc. ALL under warranty, no probs, big reciept with all part numbers on. No probs since.

The good news: You can check your car. Open the bonnet, and look down to the passenger driveshaft inner CV joint. There should be a PINK band around the CV or gaiter. If not, the car is allegedly from the odd batch, and should be modified accordingly by the dealer.

All of this must be taken with the usual caution; I'm not responsible for any of the above, and can't gaurantee it as fact, but the guy was a knowledgeable chap, proper good guy, very honest considering I was buying car. Hope this helps clarify things for all, be interested to know who has and has not band, milages etc, to see if above is correct.

End Quote

Further info for you, the parts used to fix mine at dealer, job description: Drive shaft adrift, remove & strip transmission, fit modified planet gear, re-build fitting new driveshaft.

09159-18008 Hub nut
09205-05007 spring pin
27341-60j01 gear
27432-70c00 oil seal
44102-60j01 drive shaft
44111-65d00 snap ring

Hope this helps someone, please remember mine's a 2004 spec uk car, and it's only what i was told by previous owner and info from invoice. Anyone who doesn't like this info being here, please remeber this is a safety issue and adjust your opinion accordingly! I'm just the messenger so don't shoot me!

Feel free to email through forum.

Awesome info, cheers for posting

Does anyone have the pink band?

I just checked mine and there is no pink band

My Ignis Sport was built in Nov 2003, not sure when the last build was (for models imported into Australia) but mine would be pretty close I thought?

If anyone does have the pink band could they post a photo? or send it to me in an email so I can post it? admin@redlinegti.com.

i drove my car for over 3100okm now, i don't have this problem or the pink band, i have the first group of ignis sport to come to australia bulit in august 2003

My car was also built in August/September 2003. It doesnt have the pink band either. I've only done 9000km, and no problems so far....

Sorry, forgot to menion I had 29000k's on the clock. I must admit I do worry about it now.

Mine just ticked over to 20,000.. however my cousin pointed out to me (in the first 5000kms) that my left wheel makes a clunking noise when I hit very small bumps in the road.. he reckoned the drive shaft was loose.

Are they meant to have any play when you get under the car and shake it by hand? Mine does.

Hi again all

Hope the pink band thing isn't too much of a headache; it was on the Suzuki UK database as a reference to see if the correct driveshaft was fitted. It is highly possible the situation with pink bands etc is different in Oz? Apologies for hassle caused if this is the case in the end, obviously only trying to help and not panic! similar blackout on info in UK, just happened to get car off a guy in the know.

Hopefully the info and part numbers I posted above at least arm you a little when talking to dealer part departments. FYI, anyone over here that had the problem had it fairly early in terms of mileage.

With regard to driveshaft 'play', the shaft should 'float' a little from end to end, ie move into and out of each CV joint. (jacked up at full drop this won't be the case, can usually feel float with car on ground) In my opinion, the CV joint spline that fits into gearbox shouldn't have any major play.

Having said that I'm not mega familiar with Ignis mechanically yet; if in doubt, get 2 cars together and compare, especially if you can find one with and one without problem in same area.

mines pushin 45000 in 15 months and i havent had any issues yet.....

This is the photo of the pink band AndrewC sent me. Looks a lot more obvious than I was expecting, and I know I definitely don't have one. Wondering if it is only a UK thing though

I just had a look at mine and I have the pink band aswell, I thought that it might be something a little smaller like around the actual shaft but mine looks exactly the same as the above picture.

EDIT

I had the problem at just over 20,000km