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Old 30th October 2016, 16:18   #166
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Default Re: Our Marshal DI 4x4 NGCS

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Assuming you meant "beating" [re: the original trans. crossmember] and in that case, it's more likely been a great number them! Though it wasn't mentioned on my to-do list, I'm planning to redesign it to gain an inch or two of ground clearance - perhaps complete removal in favor of a piece of inverted heavy-gauge 4" c-channel and/or the newer-style low-profile rubber trans mount would do the trick. I don't do hard-core offroad, but these low hanging bits are what get me hung up when the snow gets deeper.
Just an inexpensive little DIY FYI for anyone else looking to gain a little GC (Ground Clearance) on a Jeep / misc. Mahindra product without having to increase CG (Center of Gravity - via bigger tyres, longer shackles, more radiused springs, etc): A definite win-win situation...

I suppose it was when I inadvertently drove over a huge stone in Solang Valley (also cracking the oil chamber) that I did this to my already well-battered and IMO too-low-hanging crossmember.

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...Creating the perfect excuse for this long-intended upgrade...


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...Which took me from this:


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To this (photo angle's a bit different but note the distance from the main frame rail or silencer pipe to the bottom of the crossmember):


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... Gaining at least an inch or two of mid-chassis GC in a pretty sturdy configuration. Probably could gain even more advantage by utilizing a newer-style rubber mount, which is lower-profile.

Bolted in easily...


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...and no issues in the nine days of stress-testing on some of the worst roads out there (Spiti/Kinnaur, as recounted last week in this thread).

The cost: an approx 2-3ft length of 4" c-channel, few bolts/nuts, and a couple cutoff wheels for the angle grinder... and a couple hours of work running into evening darkness...(as so often seems to happen)

Regards,
Eric

Last edited by ringoism : 30th October 2016 at 16:32.
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Old 6th December 2017, 11:37   #167
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Default Re: Our Marshal DI 4x4 NGCS

Loooong time no see Ringoism. How have you and your Marshal been?

Please post some updates.
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Old 10th December 2017, 22:21   #168
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Default Re: Our Marshal DI 4x4 NGCS

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Loooong time no see Ringoism. How have you and your Marshal been?

Please post some updates.
We're fine, Marshal doing 30kms daily school duties but i'm badly neglecting maintenance the past few months on account of producing these wood- burning stoves, very urgent as the snows approach.

Our Marshal DI 4x4 NGCS-img_20171103_10520101.jpeg

Hopefully will have completwd 25+ units by month's end. Long, hard work and not a lot of profit margin, but satisfying in some ways...

Marshal to-do list post- December:

1. Power steering (for wifey's sake)
2. front driveshaft u (cross) joints & yoke
3. Clutch (not slipping but drags a little and feels hard, despite lubrication and adjustment, so likely pressure- plate issue)
4. Headliner upholstery and painting of interior door metal and door jambs
5. Several lighting issues.
6. Differential- ring gear maybe, has been howling at speed for years.
7 Wiper motor high speed not working

Etc etc

Most urgently the (annual) selfstarter rebuild, as we're having to roll- start it these cold mornings...

Picked up an old Machismo500 besides... but that's another story/thread.

- Eric
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Old 10th December 2017, 23:04   #169
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Default Re: Our Marshal DI 4x4 NGCS

Over the course of 2017, the car has carried us to some truly lovely spots, most of them not too far from home. No time for an autumn journey this year (Spiti/Kinnaur/Banjar in 2016, Lahaul in 2015), but can't say we were impoverished:

Our Marshal DI 4x4 NGCS-img_20170307_1637014.jpg

Our Marshal DI 4x4 NGCS-img_20170310_105601.jpg

Our Marshal DI 4x4 NGCS-img_20170311_172215.jpg

Our Marshal DI 4x4 NGCS-img_20170313_153239.jpg

Our Marshal DI 4x4 NGCS-img_20170313_153856.jpg

Our Marshal DI 4x4 NGCS-sam_2085.jpg

Our Marshal DI 4x4 NGCS-sam_2095.jpg

Our Marshal DI 4x4 NGCS-sam_6225.jpg

Our weekly car-washings under the bridge became a Saturday afternoon ritual and it seems family tradition...

As usual did some service hauling firewood as well...

Rickety / neglected as it is, the car has been reliable and we're grateful to have it. If I felt like buying something that cost several times what this has, I could probably be tempted to trade up to something like a second-hand AWD Fortuner... but other than that can't think of much that would serve our usual purposes so well...

-Eric

Last edited by ringoism : 10th December 2017 at 23:08.
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Old 29th January 2018, 18:32   #170
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Default Re: Our Marshal DI 4x4 NGCS

A bit of long overdue upkeep:

First in order, considering the cooler weather, was the self-starter:

Our Marshal DI 4x4 NGCS-img_20180119_16552301.jpg

I have to say, in the six years we've owned this car, it's been the most problematic component, requiring yearly rebuilds. Hack mechanics as usual, using very little grease, assembling things gritty with low-grade desi parts and no real consideration of correct bushing tolerances... and then charging more for labor than I do for any of my own engineering services. They insist it's normal - just have to rebuild them yearly - which is to say I need to hand them over a couple grand annually. No thanks.

Ultimately the armature would get off-center enough to start dragging on the field poles, and in cold weather, would run the battery down quickly and not always manage to fire the DI at all.

So I figured it was time to do it myself.

Our Marshal DI 4x4 NGCS-img_20180120_15214802.jpg

Reground the armature shaft on the long end, as it was worn to a taper. Then installed a slightly undersized bushing, and did a little juggad in the form of a cap to seal out the dirt and retain the grease; also added a new "Bendix", as it had been failing to engage lately. A trickle-charge of the battery for a good 20hrs also seemed to do wonders, though the Exide "Little Champ" seems quite inferior to the Amaron Harvest in use earlier. Let's see how it holds up this time:

Our Marshal DI 4x4 NGCS-img_20180120_15214801.jpg


********

Lighting: I don't think there was a single bulb on the car that was consistently working properly. A brake light on one side, tail light on the other, and the headlights, high or low beam, were completely erratic. So had to play around with the wiring/sockets/bulbs a bit.

Besides that, presumably a young vandal had ripped one of the LED strips that had been serving effectively and unobtrusively as front marker lights. So replaced both with these Chinese units sourced last year in Mizoram - they were supposed to work as marker-cum-indicator, but mysteriously didn't, so just wired them in common together. I never really liked the ungainly, plasticky stock M&M units - these are much brighter and very neat, being flush-mounted:

Our Marshal DI 4x4 NGCS-img_20180129_133500.jpg

Both the inner small lamps nearer the grille and the markers on the fender sides have been wired as indicators, which seems sufficient to that purpose, leaving these as running/marker lights.

**********

The clutch had been giving trouble the past few months - not slipping or chattering much, but dragging (difficulty engaging 1st/reverse from a standstill), getting hard, and inexplicably requiring very frequent adjustments, till the available fork travel was minimal.

The cause:

Our Marshal DI 4x4 NGCS-img_20180124_12022701.jpg
Our Marshal DI 4x4 NGCS-img_20180124_12023801.jpg

And a lesson learned - this is a Rs100 part ("fork") that I neglected to change when the disc/pressure plate were changed five years ago. It subsequently wore all the way through the metal, as seen, where it rests on the ball-pivot. The disc had plenty of life left in it; the pressure plate may or may not have been the cause of the hard action, and the release bearing was unexpectedly getting rough/dry too (think my wife was driving with her foot on the pedal sometimes).

Anyway, now replaced it feels about like driving a Maruti now - very light and smooth. As a tip for anyone with a Mahindra product: According to our local parts guy, most M&M clutches are basically identical, but are packaged / labeled with differing MRP's dependent upon class (segment) of vehicle basically. So a Scorpio unit would apparently be a lot more pricey than the Pickup-packaged one I got, priced at rs3,700 MRP (genuine).

*****

Booster: Lastly, I used to joke that this vintage Jeep was equipped with "ABS" because in truth, it was just about impossible to lock up the brakes. Regardless of how hard the pedal was pushed. I'd assumed it was because it had been converted to disc brakes with no corresponding upgrade to booster, or even addition of a proportioning valve. But a local mechanic had told me that the small booster actually ought to work fine, and the front/rear bias did not seem imbalanced, so got to thinking the booster itself may be defective.

On my last visit to Delhi fellow t-Bhpian Vikrant had offered a nearly new spare booster he had laying around (he'd put a larger one in his own 4x4 Marshal), and I figured I'd give it a try.

Our Marshal DI 4x4 NGCS-img_20180129_133533.jpg

...Which is to say that my ABS has disappeared, the brakes are now STRONG, and I don't hurt my knees anymore trying to hold it on a hill...

****

Now all we need to make it truly drive like a small car would be power-steering... the kabbad in NerChowk had a complete setup mid-year 2017, for which he wanted rs8,000 - but has since sold it off, so need to start looking for another... shouldn't be too tough now that Bolero Pickups now come with it, and they tend to get wrecked pretty often in the hills.

All for now,
Eric

Last edited by ringoism : 29th January 2018 at 18:43.
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Old 29th January 2018, 19:29   #171
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Default Re: Our Marshal DI 4x4 NGCS

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Originally Posted by ringoism View Post
And a lesson learned - this is a Rs100 part ("fork") that I neglected to change when the disc/pressure plate were changed five years ago. It subsequently wore all the way through the metal, as seen, where it rests on the ball-pivot.
Thanks. Though it is normally changed during a clutch overhaul, I'll now place it in the must be changed category. Similarly in some models, the linkage includes a short link consisting of a cable with two connectors crimped on. Another part prone to almost sudden failure, and in the must change category.

Don't ignore a hard clutch. It is what I blame for my knee and hip trouble!

Regards
Sutripta
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Old 29th January 2018, 20:00   #172
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Default Re: Our Marshal DI 4x4 NGCS

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Thanks. Though it is normally changed during a clutch overhaul, I'll now place it in the must be changed category. Similarly in some models, the linkage includes a short link consisting of a cable with two connectors crimped on. Another part prone to almost sudden failure, and in the must change category.
Indeed, that short cable had broken just before the clutch job - on account of the hard action, I suppose. Replacement only rs50 I think. Re: the fork, I'm pretty sure I remember the previous mechanic repeating the old "Chalega" refrain when I asked about installing a new one (very rare is the conscientious / trustworthy mechanic)!!! I confess I'd never seen this happen on any previous car.

Labor for the clutch job was rs1,000 and in light of the aging release bearing, the fork failure was probably a blessing in disguise.

Good hearing from you, Sutripta.

-Eric
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Old 17th February 2018, 09:35   #173
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Default Re: Our Marshal DI 4x4 NGCS

Passing through Buruwa last weekend, I am pretty sure I spotted this legendary Marshal...
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