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Old 28th December 2010, 23:20   #256
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Default Re: Mahindra Classic - Jeeping exercise

Steering box confusion got resolved, I have decided to stick to the stock RANE gear box as the damages to chassis with other models were not really impressive to me. I dropped the plan of PS conversion too as the modifications for steering column also didn't convince me, thus the original OE steering box taking place.
Mahindra Classic - Jeeping exercise-28122010001.jpg

Mahindra Classic - Jeeping exercise-28122010008.jpg

Mahindra Classic - Jeeping exercise-28122010013.jpg

I'm still waiting for you guys to give me your inputs for the FFRA and other issues discussed in the previous posts.

When we removed the steering box, I also removed the starter to fix some problem in the Bendix. Need to replace the same with a good Electrician tomorrow.
Mahindra Classic - Jeeping exercise-28122010004.jpg
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Old 29th December 2010, 23:50   #257
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Default Ffra

What is required to get the SFRA of Mahindra classic converted to FFRA setup?

I'm still not sure about 23" and 32" axles, may be it is the correct size. I will have that validated tomorrow.
  1. one 23" both side 19spl axle
  2. one 32" both side 19spl axle
  3. two Flanges(8 hole type with 19 spline, Need to drill two holes for accomodating the dowels from hub)
  4. two wheel side oil seals
  5. two grease cups with a bolt (8 hole type)
  6. two scorpio hubs with dowel
  7. two spindle aka. subaxle
  8. four wheelhub bearings

The scrap vendor in Pudupet from whom I picked the Scorpio hubs told me that the carrier plate and brake drum from existing setup will straight fit into the FFRA conversion and need not procure it. I will see if I could use the same after talking to my mechanic tomorrow.

The spindle or subaxle inner dia is not actually matching to flange/axle size hence it was lathed to increase the inner diameter.
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Old 30th December 2010, 12:56   #258
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Default Full Floating Rear Axle conversion

Hi Friends,

I thought I will post the picture of variuos parts required for FFRA setup in any 48.4" axle width jeep.
Mahindra Classic - Jeeping exercise-30122010001.jpg

From the above picture
  1. 8 Holes Grease cup bolt(this actually holds the axle with flange
  2. 8 Holes flange with 19spl(need to drill 2 holes to accomodate dowels in the hub)
  3. Grease cup
  4. Axle inner oil seal
  5. Hub packing
  6. Hub with 8 holes and 2 dowels (pinje? as referred by mechanic)
  7. Spindle aka. Sub axle(The 6 holes in the spindle mates with the studs in the differntial housing and actually connects the diff. housing with rest of the axle parts.)
  8. RH Axle 23" length with 19spl both side
  9. LH Axle 32" length with 19spl both side
I need still more parts to complete the FFRA conversion which are:
  1. axle outer oil seals
  2. 2 small size hub bearings
  3. 2 big size hub bearings
  4. wheel studs
  5. hub bolts
There is a minor changes in what I have listed in my previuos post as well. The hub is not from Scorpio as the Scorpio's PCD is not same as the Jeeps. Not sure which vehicle this 8 hole hub had come, I got it collected from Scrap vendor. I discovered the PCD issue when my mechanic tryed to match the wheel stud holes with the ones in hub.
Mahindra Classic - Jeeping exercise-30122010002.jpg

Last edited by trammway : 30th December 2010 at 13:00.
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Old 30th December 2010, 14:55   #259
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Default Re: Mahindra Classic - Jeeping exercise

please post the pic of the hub, this is a critical piece of the mod and i am still trying hard to learn which 137.5 PCD came with a 8 bolt hub design, unless it is a modded one. Is the hub separated like this from the brake drum?

And I am thinking you are mixing up the drum and hub terminologies. The scorpio never needed a hub (the rear at least)...!!

Now i am totally confused..!!

While drilling the flange, you need to drill the nagaraj cup too why do you call it a grease cup?

Last edited by svsantosh : 30th December 2010 at 15:05.
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Old 30th December 2010, 15:41   #260
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by svsantosh View Post
please post the pic of the hub, this is a critical piece of the mod and i am still trying hard to learn which 137.5 PCD came with a 8 bolt hub design, unless it is a modded one. Is the hub separated like this from the brake drum?

And I am thinking you are mixing up the drum and hub terminologies. The scorpio never needed a hub (the rear at least)...!!

Now i am totally confused..!!

While drilling the flange, you need to drill the nagaraj cup too why do you call it a grease cup?

Hey Santhosh, Please refer to picture identification number 6 Hub picture is in the above post.

I have already clarified that this hub is not from Scorpio as the PCD for scorpio and our jeeps are different.

No buddy we don't need to drill the grease cup as the dowel will stay at flange level and the bolts (8numbers) will go from the outer most surface of the entire setup. The grease cup will sit above the dowels hence it is going to be 8 holes only.

(grease cup - as referred by parts dealer)
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Old 31st December 2010, 00:10   #261
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Default Full Floating Rear Axle conversion

The parts which were left out in the previously explained post is here in this post.

Please see the picture below and refer the reference codes in the list

Mahindra Classic - Jeeping exercise-30122010004.jpg
  1. Hub bolts (8x2 =16)
  2. Pinion Lockwasher (not used for FFRA conversion, please ignore this)
  3. Axle/Hub Inner lock washer
  4. Axle outer oil seal (previous post lists the inner oil seal)
  5. Axle/Hub Outer lock washer
  6. Hub nut (2x2=4)
  7. Wheel studs (will be sitting in the hub) & Wheel nuts (5x2=10)
  8. Pinion Nut (not used for FFRA conversion, please ignore this)
  9. Hub large bearing (1x2=2)
  10. Hub small bearing (1x2=2)
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Old 31st December 2010, 10:54   #262
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Default Re: Full Floating Rear Axle conversion

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Originally Posted by trammway View Post
The hub is not from Scorpio as the Scorpio's PCD is not same as the Jeeps. Not sure which vehicle this 8 hole hub had come, I got it collected from Scrap vendor.
Your mech is a genius.

The hub is from the VAN, not the FC. And the pcd is 137.5.

In the case of my jeep, all I need to do to change from the 6 bolt (no dowel) to 8 bolt (with dowel) is change the 2 flange and got 2 hubs of the VAN. Of course need to CAREFULLY drill the flange with 2 new holes to CORRECTLY fit the dowel...!!

Mahindra Classic - Jeeping exercise-31122010129.jpg

Mahindra Classic - Jeeping exercise-31122010130.jpg
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Old 2nd January 2011, 15:39   #263
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by trammway View Post
4. Snorkel fitment - Suggest me a best routing of snorkel duct as my airfilter (horizontally placed paper unit that came in MM550) placed on the passenger side firewall.

Most important thing that I don't want to loose my folding windshield for Snorkel fitment, any ideas how to achieve this snorkel installation with this constraint?

Team-BHPians,

Any one got some suggestion for me on how to achieve the snorkel fitment in my Classic considering the left side air filter box and need for fordable windscreen.

Another point of the current upgrade/restoration goes with the suspension modification as well, I'm adopting to the Janaiah's design. Thanks to Fazal sir for getting me a set of Janaiah's spring plates for my Explorer.

More information about the Janaiah's design could be found in this post:
http://www.team-bhp.com/forum/4x4-te...ml#post1469447 (Raising a Jeep's ground clearance : Options?)

After upgrading the leaf springs, I will also plan for tyre / rim change.

Last edited by trammway : 2nd January 2011 at 15:44.
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Old 2nd January 2011, 16:45   #264
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Default Re: Mahindra Classic - Jeeping exercise

99% of chances say you should sacrifice the windscreen fold-ability..!! Very difficult to retain both, else, the design would become very weird and the snorkel would stick out like a SORE thumb, else mod the wind screen to a CJ3B type and open OUT the glass when ever you feel stuffy inside.

Edit - Tiger had a FFRA, did you study it or was it too early in your jeep days? Looks like the 6 bolt design without dowel.

Last edited by svsantosh : 2nd January 2011 at 16:49.
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Old 3rd January 2011, 10:28   #265
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Default Re: Mahindra Classic - Jeeping exercise

Quote:
Originally Posted by svsantosh View Post
99% of chances say you should sacrifice the windscreen fold-ability..!! Very difficult to retain both, else, the design would become very weird and the snorkel would stick out like a SORE thumb, else mod the wind screen to a CJ3B type and open OUT the glass when ever you feel stuffy inside.

Edit - Tiger had a FFRA, did you study it or was it too early in your jeep days? Looks like the 6 bolt design without dowel.
Hmmm I'm still finding ways to install the snorkel, otherwise I'm also thinking of adopting Dr.Jones Prowler design.

Another option to install a poll parallel to the windscreen frame with a key screw adapter so it could be screwed to the windscreen when it is open and it could stand alone when windscreen is folded off.

I'm well aware of FFRA in Tiger, it was 6bolt design and no dowel etc. However with Tiger I was not much of cautious doing any technical change, so nothing registered on my mind.
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Old 3rd January 2011, 10:39   #266
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Default Re: Mahindra Classic - Jeeping exercise

Siva,

Check my thread and see how my snorkel is fitted.
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Old 3rd January 2011, 11:08   #267
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by Tejas@perioimpl View Post
Siva,

Check my thread and see how my snorkel is fitted.
Doc,

That was wonderful design of Snorkel routing, however I could see the snorkel duct placement is greatly depending on your roll bar A pillar column, which is not present in my jeep. Nonetheless what you have done in the Classic is very innovative and I feel very bad that this beauty is no more with you.
Mahindra Classic - Jeeping exercise-p7110416-1.jpg

Mahindra Classic - Jeeping exercise-p7110417.jpg

Mahindra Classic - Jeeping exercise-p7110418.jpg

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I don't think I could adopt the roll bar with A pillar as it will once again put my Classic's original dash board to a task.

I need to only check where to anchor the snorkel duct as you have done it with the A pillar column. If I could do that, I'm done with my task.
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Old 3rd January 2011, 11:25   #268
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by trammway View Post
Doc,

That was wonderful design of Snorkel routing, however I could see the snorkel duct placement is greatly depending on your roll bar A pillar column, which is not present in my jeep. Nonetheless what you have done in the Classic is very innovative and I feel very bad that this beauty is no more with you.

I don't think I could adopt the roll bar with A pillar as it will once again put my Classic's original dash board to a task.

I need to only check where to anchor the snorkel duct as you have done it with the A pillar column. If I could do that, I'm done with my task.
What you can do is have a clamp in the lower portion as circled and another screwable clamp in the upper portion. Use thumb type bolts that can easily be removed when you want to put the windshield down.

I had my reasons to sell the classic as i explained to you over the phone the other day. I feel sad everyday, but hey, that gives me more of a push to get something better (or atleast get it and then make it better!)
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Old 3rd January 2011, 13:52   #269
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by Tejas@perioimpl View Post
I had my reasons to sell the classic as i explained to you over the phone the other day. I feel sad everyday, but hey, that gives me more of a push to get something better (or atleast get it and then make it better!)
Tejas, I still hate you for selling your beauty. Let the classic's ghost haunt you for ever.!!. Just kidding ok. BTW- where is that classic now? I guess Calicut right? I havent seen any updates from the new owner.

Cheers
JC
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Old 3rd January 2011, 20:07   #270
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Default Re: Mahindra Classic - Jeeping exercise

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Originally Posted by Tejas@perioimpl View Post
What you can do is have a clamp in the lower portion as circled and another screwable clamp in the upper portion. Use thumb type bolts that can easily be removed when you want to put the windshield down.

I had my reasons to sell the classic as i explained to you over the phone the other day. I feel sad everyday, but hey, that gives me more of a push to get something better (or atleast get it and then make it better!)
Hmm the clamp is what even I was thinking, let me see how quick this is getting materializes.

I remember you were telling me about the classic, my post is only out of emotional.

I wish you all the very best for getting a much better offroader in the near future.
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