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Old 16th January 2013, 20:50   #1
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Default My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

It was around mid March 2010, that I moved over to Coorg from Dubai. This was a well planned sabbatical from my 15 yrs of Business Intelligence job, to be close to nature and some heartfelt causes. I turn to organic farming taking up an estate in Coorg, yes, very much the first generation farmer type, who make more mistakes than anything right to start with. First of which was, about my acquisition of a 89 model stock gypsy in a run down condition , that i thought would help me get to my farm 32kms from where I initially settled down to start with. Couple of days of driving ups and downs , around the winding ghats section with an underpowered engine got me to decide to overhaul the same(That this took more than a year is another story, good enough for another thread).

So with gypsy gone, and seeing almost every other estate owner owning a jeep, I decided to own one too. So I cook up the rationale for going in for a jeep , that would convince my wife and other family members for scaling down from luxuries of a ML500 and 6.3 litre Ford Expedition NBX sport . The punch line I told everyone was, ' I have become a farmer, I need to have a jeep to move around inside my farm and also use it as a makeshift utility vehicle.'. Approvals done, the search for a jeep begins.

I got fascinated with the petrol engined willys jeep, but , my 6ft height coupled with a BMI on the red scale, found myself not able to drive such jeeps including the CJ/CL series in its stock setup. MM540 was the only choice and I saw/test drove almost 7-10 MM540 with model year between 1996-2001) over the next one week. None of them were to my appeal, not due to the aesthetics but more due to the lack of feel on the drive part. Almost all of them had light bodies(could be my gut feel), and used to shake like hell on the test drives. I was initiated to the three rounds of steering play, in some of these vehicles. Finally , I land up at a private estate in Virajpet, to see a well maintained single owner 89 model MM540 in stock condition. Somehow, I connected well with the vehicle on first sight, and after a short test drive, I was so happy with the vehicle(it felt heavier than the new vehicles that I drove) and also well planted with no body rattles at all. A quick discussion with my brother on the final price and we make an offer which was accepted,INR 79000 for the 89'er. The jeep was collected the next day morning from Virajpet and was brought to Madikeri RTO for fitness certification and transfer of ownership.Initiation again to the death wobble en-route to this activity.

The 4 guna 4 fun starts from then on . The RTO officer inspecting my vehicle asked me to put the 4 wheel drive low. I knew by then that the two small levers where meant to engage the same unlike the electronic switches in my previous vehicles. But didn't know which one to move to which ever direction. Seeing my confused state of mind reflecting over my face, RTO officer helps me with the same. All four wheels engaged and the kind RTO officer marries me to my 89'er MM540 and I head straight back home.
My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!-01.good-ol-89er-mm540joinsthefamily.jpg

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One more post on the quick upgrades that were done and then I leave my flashback mode and start on with my upgrade plan - phase 1 that I am currently into.


Last edited by jmvivek : 16th January 2013 at 20:55. Reason: missed the last line
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Old 17th January 2013, 02:02   #2
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

First set of upgrades I did were the following.

1) Changed the softtop to a convertible style. Had that flying off the roof whie driving down to Bangalore on 3 and 1/2 NDMS tyres with my family, just 6 kms off Madikeri. Learned about how not to do a custom soft top.

2) Got two Premier 118NE wide comfy bucket seats and repaced front seats. The stock seats where giving me an ache at the wrong place after a few days. Moved the passenger side seat to the rear side, converting them to front facing ones.

3) Did a custom rollcage almost in line with Fazal sir's brown MM540. Taken lot of cues from the interiors

4) Reached Bangalore and got 4 Maxxis Creepy crawlers(7.00-16). Costed me INR 8300 per tyre in 2010. Bought this from Sai Iyengar and sons. They provided an excellent service. Since the tyres from fitted on to my stock rims,they suggested to put tubes . Apollo bullet 7.50-16 tubes were put in. Driven these tyres for almost 43000kms on and off-road. Still good for a retread to stock as a backup.

5) Lamda free wheeling front hubs.

6) Busted my stock engine on my first solo trip to Thekkady from Coorg towards the end of 2010. Radiator hoses were giving away right from Marayoor , say 40 kms from Munnar. Kept me going till my destination. Ended the trip a the workshop with a loud bang from the radiator. The top portion of the radiator was torn off. Mechanic identified this as an engine problem. A 2004 Xd3P oil cooled engine was sourced from Madurai, the following week and the engine swap done. Starter position had to be changed from the right side of the engine to the left side. The newer XD3P was a direct fit to mate with the existing 4spd KMT90 gearbox with T18 2 lever transfer case.

I had driven almost 15-18k kms on the older XDP 4.9 engine and have covered close to 45000kms in the new XD3P avatar over a period of 3 years. By now you would have understood that I am a fanatic , lunatic jeep driver.

Time to move on to the present. Attached some shots on my 540 over the last 3 yrs.
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My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!-05.good-ol-89er-mm540atbaotr2012.jpg

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Old 17th January 2013, 10:31   #3
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Been on team-BHP as a member for the last 1 year or so and has been a voracious reader much before the same. Have been collecting information from the various informative threads/posts put up by the following

1) Arka(ex670C) -on his inimitable off-road specific performance upgrades, Read My (My MM540XD upgrade)MM540XD upgrade - Page 17 - Team-BHP so many times.

2) Samurai - on all the intelligent questions he put up for the experts to ponder. Read his
http://www.team-bhp.com/forum/4x4-ve...hp-family.html (Mahindra CJ340 joins Team-BHP family)
at one go.
3) Fazal sir's thread on the Lynx and his MM540. http://www.team-bhp.com/forum/4x4-ve...cing-lynx.html (Introducing, The LYNX.) . The degassing bit from DB sir is something I plan to incorporate on my vehicle.
4) Sreejesh, Dhanush, Santhosh , Allan, Tejas. Suresh Stephen,Jaggu da - threads/posts have been very interesting all along.

5) trammway - who can miss him, learned that jeep has a PTO from his thread http://www.team-bhp.com/forum/4x4-ve...ercise-14.html (Mahindra Classic - Jeeping exercise) . Saw UBS sir giving a perfect example of commitment and support to a genuine jeep enthusiast.

6) I have missed some , but not to miss the info/knowledge shared in the forum by Spike(Spike_Arrestor), Dhabhar Behram, Sutripta, Sudarshan( he had me laughing hard in one thread where he refers himself as Sudarshan uncle, remember the jeep which did 140 and a fellow team-BHPian whizzed past at 300km/hr)


Each and everyone of you helped me understand my vehicle better, and I have been holding myself from any upgrades in the last 3 years to really understand the capabilities of my vehicle well in its stock setup. With support from all of you out there, I hope to get my upgrades done to satisfaction.

Jeep light weights, heavy weights and the Stalwarts...hope you are listening.


On to the upgrades...

Current setup on my vehicle.

2004 model XD3P oil cooled engine, with 4 core radiator, 5.38 diffs with 4spd KMT90 gearbox with T18 2 lever transfer case, Bosch 90AH battery.

Upgrades planned/taken-up currently

1) FFRA conversion - using 53'' 2010 model Bolero 4*4 pickup axles. The the break housing part is being changed from the existing automatic type to oldr manual type as per mechanic's adivse. According to him the recet pickups are having issues with the same. Experts, your viewpoint please.

2) Front axles - 57'' OKBJ from 2008 pickup.

3) 5.38 differentials to be retained - Spike/Arka/DB sir your viewpoint/suggestions please !

4) Disc brakes - setup take from the MM550. Need to buy the rest of the parts. Mechanic was suggesting to buy the pickup economy type round brake booster/pump a smaller one compared to the newer Bolero bigger round ones. He said this is better and dosn't interfere with the hanging pedal setup eig done along with this for the clutch and brakes. Can anyone give me specifications on what all to change, part nos appreciated. Using the MM550 dis brake setup , what should I be using , is it a ventilated disc brake setup.

5) RCBT power steering - Bolero type

6) change to 160 PCD

7) MM army type air filter. Change current oil filter to paper type to enhance air intake

8) Fuel tank position under passenger seat, doubling the capacity using a custom built one with a reserve 6-10 litre feeder tank.

9) Starter solenoid to be changed to the dual setup one - thanks to DB sir's advise

10) Degassing tank to be setup. Hope I don't have to do anything different with an ac setup on this.

11) Need to change the existing water pump MM540 XD3P 2004 model type.The earlier one busted before last years Avalaconda and had to replace this with a duplicate one. haven't given any issues as yet, but I saw DB sir's point on the duplicates not having some of the inbuilt passages for water circulation. Don't know where to get this. Duplicates are available in plenty.

12) add a PTO driven air compressor.

13) Replace the existing fan to the scorpio type viscous coupled one

14) Larger capacity alternator . Plan for an ac upgrade , if possible. Alternator position to be moved to the highest point

15) See if I can add a RPM meter to my XD3P

16) Skid plate for the leaf spring U-Bolts, Diffrential guards / skids - custom fabricate

17) A practical Rollcage cum softtop frame

18) Breather pipes to be be extended, both diffs, transfer case

19) Seal all electricals

20) Wiper motor to be changed from the existing single speed. Need suggestions on better ones that can ft the MM540 windscreen

21) Lights to be upgarded to the 140 watts type...need tto refer to DB sir's post

22) Rear innova seats as per Jyobeb's thread

23) Coolant hoses to be changed to scorpio type

24) Winch plate/mounting to be fabricated as per Arka's specs in his thread.

25) Spare tyre cum High lift jack holder, swing bar type to be fabricated.

26) custom make wheel arches to suit the wider stance(fingers crossed on the outcome on this)

27) Body work/tinkering/paint job

Last edited by jmvivek : 17th January 2013 at 10:32. Reason: too many typos
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Old 17th January 2013, 12:03   #4
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Interesting write-up!

There are a lot of wanna-be jeepers on t-bhp. Yours truly included, my half dismantled MM is lying in the corner of a workshop 20 odd kms from where in am.

But you seem to have thought things through pretty well. There's not doubt about the fact that t-bhp is THE best thing that ever happened, as far as Indian auto enthusiasts are concerned.

If you don't mind, could you also put up the cost incurred as you go about customising your jeep?

All the best and more importantly, keep us posted!
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Old 17th January 2013, 12:35   #5
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Dear jmvivek - by the time you complete 27 items in your list, you will tear out whatever hair will be left on your head. That was in a lighter vein, on a serious note, please don't go overboard, you will not realize the value for the money that you will spend on the vehicle. Instead, enjoy the vehicle as you have it.

If money is not the issue, you know what to buy!

Best regards,

Behram Dhabhar
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Old 17th January 2013, 14:03   #6
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Quote:
Originally Posted by DHABHAR.BEHRAM View Post
Dear jmvivek - by the time you complete 27 items in your list, you will tear out whatever hair will be left on your head. That was in a lighter vein, on a serious note, please don't go overboard,
If money is not the issue, you know what to buy!
Behram Dhabhar
Thanks for your comments/advise DB sir. As I had mentioned earlier, I have developed a relationship with this vehicle and will be with me till anything really warrants otherwise)god forbid). I will only do what is absolutely necessary on this vehicle and will be used as a vehicle to use in medium to extreme off-road situations/events. AC is something I am still not decided yet. Rest everything, I should be able to do it correct, now that I have your eyes overseeing the project.

For everything else I will be going in for an AC Thar, Me and my wife had fell in love with the non-ac version itself when it came out and still not very finicky about the ac part except for long distant drives, now that we have baby in our family who is yet to get onto to 4*4 mode.was holding back due to too the other vehicles we currently own.

Quote:
Originally Posted by coloneljasi View Post
Interesting write-up!

There are a lot of wanna-be jeepers on t-bhp. Yours truly included, my half dismantled
All the best and more importantly, keep us posted!
You are very true about Team-BHP forum and the members. This is where I got baptized/initiated on 4*4. Will definitely share the cost details as and when it is covered.
Thanks once again for your wishes/comments.
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Old 18th January 2013, 04:07   #7
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Bodywork was already on in the last couple of days. Some photos to record the progress till date.
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Axles came in today. Both FFRA 53 inches and OKBJ 57 inches procured as per guidelines from ARKA. The FFRA has been sent to the lathe late evening to swap the tubes. Will work on the Front axles tomorrow to get the alignment set.

Need some guidance from experts on points 3 & 4 post #3. Need part nos/item list to order the same. Confusion still on the Braker booster type that needs to be procured as explained in point 4.

I am retaining the 5.38 diffs and I have read about the importance of differential gear lash setting that needs to be done from this post. http://www.team-bhp.com/forum/4x4-te...s-lockers.html (Dependable 57" axles, diffs and lockers) , Need guidance on 5.38 differential gear lash setting.

"Setting Backlash In A Rear Axle - sourced from the net
When installing a ring and pinion, you have to have a perfect installation or else you are going to destroy the gears and bearings.
One of the critical measurements that must be made is setting your backlash. What is backlash? When you turn the pinion on your differential it will turn a specific amount of space before it actually contacts the the ring gear to turn your axles. If you have too little backlash the pinion is jammed into the ring gear and this will produce a lot of friction and heat and will lock up your rear axle. It will not turn freely. If you have too much backlash the pinion and ring gear will be too far apart and this will allow the gears not to mess properly and with the force of your motor will chip and destroy the teeth of the gears. This will cause excessive whining and will eventually destroy your axle again."


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Last edited by jmvivek : 18th January 2013 at 04:25.
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Old 18th January 2013, 07:13   #8
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

I am not going to bother giving any inputs here just for the fact that you are in Jeep Mecca, not some 'Jeep specialist' or a 'offroad specialist' shop in a maruti-riddled town or city... I am going to njoy a coogi-way of doing things by just reading stuff here. Have fun

PS - never knew Mt's can be worn out to resemble a distant cousin of NDMS :-P
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Old 18th January 2013, 08:10   #9
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Santhosh, Please don't hesitate to provide inputs on area that need specific attention/amendments, if required. The fact that I woke up in the middle of the night to do this last post is to ensure that I can collect valuable information from experienced/enthusiastic people like yourself. I am a fan of your DIY posts.

Thanks ,Vivekj
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Old 18th January 2013, 09:51   #10
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Vivek, what is your plan with the tub. Can see that there is a box sort of thing welded to it? Planning to make it as a 2 seater with a box for storage behind?
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Old 18th January 2013, 13:40   #11
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Hi Vivek, all the best on your rebulid and you sure have all the best sources here on tbhp for your Jeep. I still am running around reworking bits and pieces of my Jeep and I'm pretty sure thats going to be a never ending process. Happy Jeeping. Any idea where I can source 57" OKBJ and 53" FFRA?

Regards,
Barani
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Old 18th January 2013, 14:31   #12
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

1) Whats is automatic type brake Vs manual type?

2) how much did 58" OKBJ cost you?

3) 5.38 - GOOD for offroading, and daily use around the hills

4) interesting fuel tank setup, awaiting final pics, PS - hope you didnt create a future potential rust bucket! Anything hidden in a Jeep is BAD

5) Degassing tank - dont bother for a ol' XDp4.90... better to rebuild/replace existing system to OE condition. Why did you want it? In your words...

6) PTO Aircomp, that i can help if you manage to get a PTO!!

7) Viscous coupling sounds dirty!! Why do you want to deviate from a simple no-nonsense design?!!

8) Alternator point - good idea, try any 90 or 100Ah ALT from safari's boleros, etc. If you dont need the vacuum pump for booster brake just remove the pump behind the ALT and plug the oil holes and take care not to touch the spining shaft while engine is running. In your case you will need the pump!

9) RPM works off the alternator on diesel engines, shd be a easy DIY if you can find a lorry's Tach. Need to fiddle with it to work on 12V, else just buy a cheap tacho? Why do you need a tacho again? To see how a XDP4.90 travels from 900Rpm IDLE to 3000RPM in about 45 seconds in top gear?

10) Skid plate for u-clamp-plate - my old project, just dropped it! All the best...

11) sealing all electricals isnt so easy, better inculcate a mind set to remove-petrol wash ALT and starter after every wet OTR, even dry dusty ones cause some trouble in long term.

12) Is your wiper motor below A-Pillar, behind the steering? Get a new original motor, my AG has the motor in the same place, and 3 speeds are sufficient for my use.

13) 140 not worth it, get a correct working 90-100 with MINDA wiring kit and relays, will do the job, also new sealed beam does wonders.

14) EPDM hoses you mean? they rock!!
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Old 19th January 2013, 02:36   #13
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Quote:
Originally Posted by ArunV View Post
Vivek, what is your plan with the tub. Can see that there is a box sort of thing welded to it? Planning to make it as a 2 seater with a box for storage behind?
The box would accommodate two rear front facing passenger seats with lockable storage area. Thats the plan.


Quote:
Originally Posted by commander View Post
Hi Vivek, all the best on your rebulid and you sure have all the best sources here on tbhp for your Jeep. Any idea where I can source 57" OKBJ and 53" FFRA?

Regards,
Barani
Thanks Bharani. My mechanic sourced these for me from Madurai.

Quote:
Originally Posted by svsantosh View Post
1) Whats is automatic type brake Vs manual type?

Thats' what the mechanic told me about newer pickups colloquially. He said this is a failure in most of the Mahindra pickup/utility vehicle and they revert to the manual one. Basically he was referring to the auto adjusting brake liners compared with the manual adjusters.

see the info provided below..
"Brake Adjuster * *For the drum brakes to function correctly, the brake shoes must remain close to the drum without touching it. If they get too far away from the drum (as the shoes wear down, for instance), the piston will require more fluid to travel that distance, and your brake pedal will sink closer to the floor when you apply the brakes. This is why most drum brakes have an automatic adjuster.
Now let's add in the parts of the adjuster mechanism. The adjuster uses the self-actuation principle we discussed above.
As the pad wears down, more space will form between the shoe and the drum. Each time the car stops while in reverse, the shoe is pulled tight against the drum. When the gap gets big enough, the adjusting lever rocks enough to advance the adjuster gear by one tooth. The adjuster has threads on it, like a bolt, so that it unscrews a little bit when it turns, lengthening to fill in the gap. When the brake shoes wear a little more, the adjuster can advance again, so it always keeps the shoes close to the drum.
Some cars have an adjuster that is actuated when the emergency brake is applied. This type of adjuster can come out of adjustment if the emergency brake is not used for long periods of time. So if you have this type of adjuster, you should apply your emergency brake at least once a week.

"

2) how much did 58" OKBJ cost you?

full set including the disc would net around 15000 INR.

3) 5.38 - GOOD for offroading, and daily use around the hills

I was using the 4.88 till the BAOTR2012. Was pretty happy with it. Suresh Stephen suggested th 5.38 and thats when I started learning about the differentials and crown pinion and the related ratios. The difference on the crawl speed and control on ups and downs are superb. I have driven 570km covering two ghat sections and bit of highway driving. Drives well around 70-80km/hr range. mileage has dropped by 2kms. But does make a difference as I like to approach obstacles is a sedate manner.

4) interesting fuel tank setup, awaiting final pics, PS - hope you didnt create a future potential rust bucket! Anything hidden in a Jeep is BAD

I understand what you are referring to. I have got the primer done on
places which goes under the welding/cladding. Moreover has asked the bodybuilder to take extra time to seal any open places , if at all during the welding process itself.I have been a bit careless transporting salt based fertilizers on the tub. That has really killed the running board. Thanks for highlighting.


5) Degassing tank - dont bother for a ol' XDp4.90... better to rebuild/replace existing system to OE condition. Why did you want it? In your words...

No, No , No...You didn't read my story in the beginning very well. I had busted the XDp4.9 and has move to a 2004 XD3p with an oil cooler. The resons why I thought about the degassing tank are one too many as mentioned below. Do let me know , if this helps;
a) If I drive consistently over 86 km/hr the temperature rises upto the 90 < 100 mark.
b) This happens in steep ghat section also , if I drive rally style, which I do many a times getting back from farm
c) Either I have to refill 2-3 ltrs of water/coolant every 5-7 days , if I do ghat section or do high-speed driving at 80+km/hr. Otherwise I have to do this once in two weeks for normal driving.

The heating part , I am not sure if it is due to the duplicate water pump I have fixed since I haven't been able to source the original for the XD3p oilcooled type.

By using a degassing tank setup, I thought I can address all three issues at one go.


6) PTO Aircomp, that i can help if you manage to get a PTO!!

Enlighten please. My mechanic was suggesting to go for the leyland tie aircomps and some addons to the PTO output on the transfer case. I will get more clarity on this from him to understand the setup he has planned and share with you.

7) Viscous coupling sounds dirty!! Why do you want to deviate from a simple no-nonsense design?!!

I had thought about this with reference to the issue highlighted under point 5.

I have to either do this or go for the thermostat based addon electric fan which is mostly what I might end-up doing.

Electric Fan = Less Power Drain & Less Cooling
Viscous Fan = More Power Drain & More Cooling


8) Alternator point - good idea, try any 90 or 100Ah ALT from safari's boleros, etc. If you dont need the vacuum pump for booster brake just remove the pump behind the ALT and plug the oil holes and take care not to touch the spining shaft while engine is running. In your case you will need the pump!

Will do, Thanks.

9) RPM works off the alternator on diesel engines, shd be a easy DIY if you can find a lorry's Tach. Need to fiddle with it to work on 12V, else just buy a cheap tacho? Why do you need a tacho again? To see how a XDP4.90 travels from 900Rpm IDLE to 3000RPM in about 45 seconds in top gear?

Smiling this side. Its XD3P with 5.38 diffs. Why I need this is purely from my requirement to understand the RPM levels on different inclines based on the non-aggressive approach I do. This would help me understand the jeep better and be ready with the correct tapping on my accelerator/gear ratios on different obstacles.


10) Skid plate for u-clamp-plate - my old project, just dropped it! All the best...

Why did you drop this project. I am ok with the design for the u-clamp. Need to come out with something for the front end of the spring leaves on the front side. I have had this scraping on rough patches where the approach/departure angles are very tight. This is in extreme case.Like trying to climb up a 45 deg incline.

11) sealing all electricals isnt so easy, better inculcate a mind set to remove-petrol wash ALT and starter after every wet OTR, even dry dusty ones cause some trouble in long term.

Good idea. But also I need to reroute some of the wires and also setup a fuse box to bring in sanity to that area.

12) Is your wiper motor below A-Pillar, behind the steering? Get a new original motor, my AG has the motor in the same place, and 3 speeds are sufficient for my use.

Yes, will do accordingly. Does this require any changes on the wiper mountings.

13) 140 not worth it, get a correct working 90-100 with MINDA wiring kit and relays, will do the job, also new sealed beam does wonders.

I do have this currently but not enough in the conditions that I drive.I do non-stop night trips 570 kms between Thekkady,Kerala and Madikeri, Coorg. With the 6-8 high beam lights from Volvos enroute, I really need an upgrade . I think I was using a 100-110/130 earlier, but this burned the bulb socket holder which comes in ceramic. Got this from Car automobiles Bangalore

14) EPDM hoses you mean? they rock!!
Yep, Hope it does. I have had issue with this hose only once 2 years ago, whe my Scorpio turbo needed a head gasket replacement and the negine was overheating . ONe of the radiator hoses was going kaput , if i take the vehicle over 50km/hr. I remember driving from Trivandrum to Bangalore non-stop at 50km/hr when this happened since the TVS service centre quoted be 90k for the repairs and 2 week time, where as ,my regular mechanic resolved this issue with a10k expense.


Now , I ned some help with the disc brake setup/parts/part nos. Guidance much appreciated.
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Old 20th January 2013, 12:34   #14
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Work on the mechanicals bit slowd down in the last two days due to delivery commitments on three other vehicles at the workshop. Front axle replacement to be done tomorrow. Disc brake conversion and power steering (RCBT power steering - Bolero 4*4 type) to follow. Rear axles will come back on Wednesday with the tubes swapped. Bodywork has had good progress. Attached pics for FYR....

Front 4WD : Full floating hypoid type,ratio 5.38 : 1 getting dismantled.

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Front 4WD : Full floating hypoid type vs. OKBJ type bing installed

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Front 4WD : Full floating hypoid type - measurement - 45 inches end-end as shown in pics


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Front 4WD : OKBJ type bing installed- measurement - 50 inches end-end as shown in pics

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No change on the bed to bed measurement - Front 4WD : Full floating hypoid type vs. OKBJ type bing installed

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Oil seals SS type(didn't get the MM ones) for the differential housing. Work on this to be done tomorrow
. Some parts for disc brake conversion also bought. going in for the single caliper type/booster/vacuum pump alternator as available in old MM pickup. trying to get a 100AH alternator. Hanging pedals already sourced.

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Meanwhile body work has had good progress...

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Regards....
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Old 21st January 2013, 20:08   #15
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Join Date: Dec 2011
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Default Re: My good ol' 89'er MM540 with 4 wheeldrive , smokey on my tail!

Aaargh!!!There goes my PMP experience....DB sir ....I have started pulling out my hair , one by one(with whatever is left with on the same )

The guy assigned to setup the front axles/differentials took a whole day to move the diff from the old housing to the new one . Was expecting the workshop to complete the front axle setup day before yesterday, today...now, will hpe to have this completed tomorrow. Just gave the senior mechanic and the team a pep-up talk and a piece of my mind today, and hass been promised that things will be done properly tomorrow.

Anyways...was expecting to get this vehicle with the mechanicals done for the BAOTR2013. But the work was held up for 45 days before it got kicked off because of other commitments by the workshop. So will be driving in my MG410 or my bro's MM540 for BAOTR2013.

WIP updates as usual....Name:  019.good ol 89er MM540Bodywork1.png
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Noticed a slight play on the front differential crown / pinion setting. It was noticed that the pinion teeth has had some wear over the last one year.Guess, the front differentials were not set properly last time when I changed to 43/8(5.38) from 4.88. Have a backup of 4.88 anyways. Will have to source a good 43/8 set and keep as a backup. Strange thing that I noted is that the wear is only on the pinion teeth . Nothing significant on the crown wheel. Wondering why?

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