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Old 30th January 2009, 12:37   #31
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Default Upgrade - Part II

Once the dates were finalized for Munnar OTR, I decided to upgrade my MM540XD a bit more.

The Following Work was done

1) Strip the old rusted body
2) Strip/Prime/Paint the Chassis
3) Install a new Tub (old 1987 MM540DP) and new Body beds.
4) Change the rear Axle to Bolero

Regards,

Arka
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Old 30th January 2009, 12:49   #32
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Originally Posted by ex670c View Post
Once the dates were finalized for Munnar OTR, I decided to upgrade my MM540XD a bit more.
Only to complain later that Munnar trail was not challenging enough.
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Old 30th January 2009, 13:44   #33
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Question

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Originally Posted by ex670c View Post
...3) Install a new Tub (old 1987 MM540DP) and new Body beds....
Arka, that tub looks familiar ??
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Old 30th January 2009, 18:30   #34
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Quote:
Originally Posted by ex670c View Post

The Following Work was done
1) Strip the old rusted body
2) Strip/Prime/Paint the Chassis
3) Install a new Tub (old 1987 MM540DP) and new Body beds.
4) Change the rear Axle to Bolero
Hi Arka, are you going to rust proof it after painting? What will you use to do this if so?

Why did you change to Bolero axles? Wider stance?
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Old 31st January 2009, 11:39   #35
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Default Wider Axles

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Originally Posted by DirtyDan View Post
Hi Arka, are you going to rust proof it after painting? What will you use to do this if so?

Why did you change to Bolero axles? Wider stance?
Hi Dirty_Dan,

I will sand blast the body and do the minor tinkering and then considering one of the following Primers

1) Polyurethane Primer
2) Expoxy Primer
3) Zinc Sulphate
4) Red Oxide

While tinkering I have given strict instruction not to use Bondo/metal Paste.

Because the metal paste absorbs water and rust the sheet metal.

Bolero Axles.

After the Front OKBJ conversion the track difference was 6".
1) Vehicle was looking very funny
2) I wanted to switch to One Piece FFRA. The older setup the outer flange develops play/slack and cuts the axle splines. ( suffered that twice)

Also wrt NGCS MM550XD (post 2004). They use 53" Front and Rear Track.

Last edited by ex670c : 31st January 2009 at 11:41. Reason: typo
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Old 5th February 2009, 10:54   #36
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Default Chassis Painting and Body Swap

The Following work was done

1) The Old body was removed from the chassis
2) The chassis was scrapped of old paint
3) Chassis was washed with washing soda
4) Chassis was primed & painted
5) New Body (1987) was fitted with new body beds/mounts
Attached Thumbnails
My MM540XD upgrade-dsc00657.jpg  

My MM540XD upgrade-dsc00661.jpg  

My MM540XD upgrade-dsc00662.jpg  

My MM540XD upgrade-dsc00698.jpg  

My MM540XD upgrade-dsc00700.jpg  

My MM540XD upgrade-dsc00706.jpg  

My MM540XD upgrade-dsc00715.jpg  

My MM540XD upgrade-dsc00716.jpg  

My MM540XD upgrade-dsc00720.jpg  

My MM540XD upgrade-dsc00721.jpg  

My MM540XD upgrade-dsc00722.jpg  

My MM540XD upgrade-dsc00723.jpg  

My MM540XD upgrade-dsc00724.jpg  

My MM540XD upgrade-dsc00725.jpg  

My MM540XD upgrade-dsc00726.jpg  

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Old 5th February 2009, 11:05   #37
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Quote:
Originally Posted by ex670c View Post
Hi Naren,
Could you please specify on which New or Old M&M vehicles these Diff-Ratios are used.

3.73:1 = 41/11

Regards,

Arka
Dear Arka,
I've been researching quite a lot on 4X4s available in market currently (affordable ones though). I think the new Major (CL550) comes with the differential ratio of 3.73:1. I am a real rookie in this, so maybe, i am wrong. If so, please excuse me.
Cheers,
Deepak
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Old 5th February 2009, 11:42   #38
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wonderful arka,

You are practically doing a mini restoration project. Work happening at lightening pace i suppose!! What tyres are you planning to replace your current NDMS?

Long time since we met...let us meet up some time!! :-)))))

P.S- Must appriciate your sourcing ability, you sourced rare bolero 4wd axles and now a complete body which seems to be in good condition!

Last edited by vinod_nookala : 5th February 2009 at 11:44.
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Old 5th February 2009, 12:12   #39
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Default Rear Differential

Since my front track was 57" and Rear track was 51".

I decided to change the rear track to the Bolero Differential.

The Only catch was the Bolero Differential was off-set to the left where as the MM540 differential is off-set to the right.

So I had the Bolero Differential Axle Tubes switched around.

The First Batch of Pictures -
LSD
Differential Housing and switched tubes
Inner Oil Seal
Pinion Yoke replaced the Companion Flange.
Attached Thumbnails
My MM540XD upgrade-dsc00749.jpg  

My MM540XD upgrade-dsc00751.jpg  

My MM540XD upgrade-dsc00755.jpg  

My MM540XD upgrade-dsc00756.jpg  

My MM540XD upgrade-dsc00761.jpg  

My MM540XD upgrade-dsc00763.jpg  

My MM540XD upgrade-dsc00764.jpg  

My MM540XD upgrade-dsc00765.jpg  

My MM540XD upgrade-dsc00766.jpg  

My MM540XD upgrade-dsc00767.jpg  

My MM540XD upgrade-dsc00768.jpg  

My MM540XD upgrade-dsc00769.jpg  

My MM540XD upgrade-dsc00772.jpg  

My MM540XD upgrade-dsc00773.jpg  

My MM540XD upgrade-dsc00788.jpg  

My MM540XD upgrade-dsc00801.jpg  

My MM540XD upgrade-dsc00802.jpg  

My MM540XD upgrade-dsc00803.jpg  

My MM540XD upgrade-dsc00807.jpg  

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Old 5th February 2009, 12:21   #40
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so, now you have a right offset diff?? What is the length of bolero rear axle? 53inch?

I thought MM550 NGCS came with 53 front and 51 rear. 57 inch of your isnt too broad?
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Old 5th February 2009, 12:39   #41
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Default Ngcs Mm550

Quote:
Originally Posted by vinod_nookala View Post
so, now you have a right offset diff?? What is the length of bolero rear axle? 53inch?

I thought MM550 NGCS came with 53 front and 51 rear. 57 inch of your isnt too broad?
Hi Vinod,

I was under the impression that the NGCS was 53" Front and 53" FFRA.

Regards,

Arka
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Old 5th February 2009, 12:48   #42
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Default 1 piece FFRA

The New 1 Piece FFRA.

Pictures of
1) Drum 139.7 PCD
2) Hub 139.7 PCD
3) Comparison of the Spindles
4) FFRA Assembly
Attached Thumbnails
My MM540XD upgrade-dsc00809.jpg  

My MM540XD upgrade-dsc00811.jpg  

My MM540XD upgrade-dsc00814.jpg  

My MM540XD upgrade-dsc00815.jpg  

My MM540XD upgrade-dsc00817.jpg  

My MM540XD upgrade-dsc00818.jpg  

My MM540XD upgrade-dsc00820.jpg  

My MM540XD upgrade-dsc00821.jpg  

My MM540XD upgrade-dsc00824.jpg  

My MM540XD upgrade-dsc00825.jpg  

My MM540XD upgrade-dsc00826.jpg  

My MM540XD upgrade-dsc00833.jpg  

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Old 5th February 2009, 13:50   #43
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Now you will have clean rear rims without oil stains!!:-))))
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Old 5th February 2009, 14:41   #44
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i can see that you have army rims, what tyres are you putting on those?

FK
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Old 6th February 2009, 11:01   #45
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Default Tyres

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Originally Posted by fk7 View Post
i can see that you have army rims, what tyres are you putting on those?

FK

MRF Sand Grip 7.50X16 for Sand and Rocky terrain

MRF NDMS 7.00X16 for Muddy Terrain.

I'm looking out for good Mud-Terrain (Maxxis/BFG) in 235-85-16/245-75-16/255-85-16
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