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Old 21st November 2008, 12:50   #1
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Default My MM540XD upgrade

Hi Guys,

The Last Few weeks I wanted to do 2 Major upgrades.
1) Manual Re-Circulating Ball Type steering assembly.(MRCBT)
2) Bolero/Invader Open Knuckle/Yoke Front Axle Conversion.

I did these together because the (MRCBT) is optimised with the Open Knuckle Axles.

1) MRCBT- Advantages
1) eliminates the Steering Idler Arm. Instead of 7 ball-joints you have 4 Ball-joints on the steering set-up.

2) better Steering Ratio i.e 23:1 lesser input torque 18Kg/cm

Disadvantages
1) Installation. The Radiator Cross-member has to be drilled/cut for the steering rod to go through.

2) Setting up the steering wheel and steering box angle. Any deflection from the original, the upgrade will become a head ache.

Why did I opt for the MRCBT steering.
1) With in 2 Weeks of changing to MRF Sandgrips in Dec2005. I damaged 2 Steering Pipes.

2) Then I upgraded to the Armada Worm & Roller type with Universal Joints.

3) That was better and as the tyres wore down the steering got stiffer, I used to change the steering idler arm center/pin every 3-4 months.

4) Finally I was on the verge of getting serious Elbow Tendonitis .

5) As a daily driver the W&RT was inadequate with the MRF Sandgrip.

6) Also I the idler arm is the weakest link in the older steering system, I discovered that after bumping into a truck on the way to Kanyakumari.

What were my options
1) Change the tyres to 6.00X16. that was not an option as I had lowered the diff-ratios to 5.38:1 so I would have to crawl slower all over Chennai.

2) Not Drive the JEEP that often

3) Bolero Power Steering .....thats 50K plus installation

4) MRCBT 6.5K + 1.5K installation

Regards,

Arka
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Old 21st November 2008, 13:04   #2
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Default Pictures of MRCBT installation

Pics 0001 to 0004
The radiator cross member the 4 Bolt Holes for the Idler Arm.
Measuring, remeasuring, marking and remeasuring the cross-member and mounting holes

Pics 0007 to 0011
Longer Reinforced Box for the C-Section Chassis. (Both Sides)
pic 0011 notice the mounting holes they have been reinforced with tube on the inside to prevent the chassis from buckling under flex.

Pics 0012 to 0020
Closing the Radiator Cross member and the Final position.
Attached Thumbnails
My MM540XD upgrade-pict0001.jpg  

My MM540XD upgrade-pict0002.jpg  

My MM540XD upgrade-pict0003.jpg  

My MM540XD upgrade-pict0004.jpg  

My MM540XD upgrade-pict0006.jpg  

My MM540XD upgrade-pict0007.jpg  

My MM540XD upgrade-pict0010.jpg  

My MM540XD upgrade-pict0011.jpg  

My MM540XD upgrade-pict0012.jpg  

My MM540XD upgrade-pict0013.jpg  

My MM540XD upgrade-pict0014.jpg  

My MM540XD upgrade-pict0016.jpg  

My MM540XD upgrade-pict0017.jpg  

My MM540XD upgrade-pict0020.jpg  

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Old 21st November 2008, 13:12   #3
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Altering the cross member for inserting the cylinder type whole ? Scary if it really affects the strength of the cross member in the chassis.
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Old 21st November 2008, 13:20   #4
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About time Arka,
I still remember my first time on your jeep !!

I was like is this what its supposed to feel like?!
I have been lifting weights all my life and I had to pull / tug / yank using all my back, neck and arm muscles.

For those who hav'nt driven or seen it first hand the MRF sandgrips makes this jeep tower over everything else on the road,...its an imposing and even intimidating piece of work!!

Last edited by Torque-ative : 21st November 2008 at 13:22.
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Old 21st November 2008, 13:58   #5
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Arka,
Looks like a big job with all the cutting & welding. Please do post on how this steering setup performs.

I also want to lighten up my 550 steering. So I might go in for the same setup or the Bolero power steering.

Keep a look out for an open knuckle front axle for me too!
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Old 21st November 2008, 15:03   #6
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Man,

Arka, only you have got guts to do such mods to your vehicle!!! People like you, Red MM340, shahnawas & others have really taken mods to the next level while mere mortals like us struggle to maintain our vehicles in stock condition!!

Lets meet up off road this weekend to check out if it can take the torture tests on our regular testing ground!!! :-)))

regards
vinod
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Old 21st November 2008, 15:46   #7
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Default Open Knuckle Front Axle.

The Front Open Knuckle Ball-Joint (OKBJ)

Track 57" 1443mm
Camber -30Degrees to +30Degrees
Caster 3Degree 30Minutes to 5Degree 30Minutes
Kingpin Inclination 9Degrees

Advantages -
1) Eliminates the Kingpin which is the main reason for Wheel Wobble
2) Sturdier than the Closed Knuckle can handle tyres upto 35"
3) Wider Track improved turning radius.

Disadvantages -
1) FUGLY
2) Reduced/Dampened Steering Re-centering.
3) Need suitable rear axles.
Attached Thumbnails
My MM540XD upgrade-pict0004.jpg  

My MM540XD upgrade-pict0005.jpg  

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Old 21st November 2008, 16:38   #8
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hey arka,
One caution though, since you are going to off road , please cut a portion of front fender on both sides as during articuation the tyres will foul them big time. Army XDB NGCS have a cut on front fenders, thats why those fancy looking black add ons to the fenders to hide the ugly cut. The indicators are moved behind fenders as the cut is where the indicators used to be before.

Hope this helps

regards

vinod
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Old 21st November 2008, 19:07   #9
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Hi Arka,

I think you are going to make me go broke. I thought I was done spending on my jeep, but you keep coming up with great ideas ;-)
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Old 21st November 2008, 21:59   #10
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Very informative thread!
You are planning to make me go broke too I guess.
Major changes done, do you foresee overcoming the previous problems or will it be a trial and error?
For now I can settle for the tow hooks on your front bumper if you have a spare pair.
Wish you the very best.

Last edited by fazalaliadil : 21st November 2008 at 22:01.
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Old 22nd November 2008, 00:11   #11
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Hi Arka,

Are you using OKBJs from Invader? Or, is it the MRCBT steering assembly that is coming from the Invader, or both?

Do you happen to know if the newest Mahindra 4x4 pickups already have the same steering and OKBJs that you are switching to? I mean these guys, the pickup and the Bolero camper.
Attached Images
  

Last edited by DirtyDan : 22nd November 2008 at 00:23.
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Old 22nd November 2008, 10:20   #12
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Default Mrcbt & Okbj & Ngcs

Quote:
Originally Posted by DirtyDan View Post
Hi Arka,

Are you using OKBJs from Invader? Or, is it the MRCBT steering assembly that is coming from the Invader, or both?

Do you happen to know if the newest Mahindra 4x4 pickups already have the same steering and OKBJs that you are switching to? I mean these guys, the pickup and the Bolero camper.
Hi Ken,

All the NGCS vehicles without Power Steering use the MRCBT and the OKBJ.

Bolero 4WD DI
Bolero Invader DI 4WD
Maxx Pikup 2WD & 4WD.

The MRCBT I bought new. The OKBJ was from a Bolero Invader.

The OKBJ has 2 Front Tracks
57" - Max Series Solid Axle models, Lower end Boleros, Marshal, Savari
53" - NGCS MM550XD & Major

NGCS Rear Axle Track Width
Maxx Series - 59"
Bolero Series - 53"
MM550XD/Major - 53"

Regards,

Arka
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Old 22nd November 2008, 10:24   #13
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Default Fender Flares

Quote:
Originally Posted by vinod_nookala View Post
hey arka,
One caution though, since you are going to off road , please cut a portion of front fender on both sides as during articuation the tyres will foul them big time. Army XDB NGCS have a cut on front fenders, thats why those fancy looking black add ons to the fenders to hide the ugly cut. The indicators are moved behind fenders as the cut is where the indicators used to be before.
Hi Vinod,

That is a very useful bit of information about the New MM550XD.

I have the Fender Flares with me, was wondering what to do with them.

Regards,

Arka
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Old 22nd November 2008, 13:23   #14
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Quote:
Originally Posted by ex670c View Post
3) Bolero Power Steering .....thats 50K plus installation
Quote:
Originally Posted by RedMM340 View Post
So I might go in for the same setup or the Bolero power steering.
Bolero power steering has a funny feel to it. Has about as much feed back as a water faucet. Maybe it just takes some getting used to but I did not like it much. Scorpio has a nice feel.

The reason I asked about the pickups is because I am considering buying a 4x4 pickup [finding a mm550 has been dismal] new since it already has the mdi3200tc and other stuff. But they changed the rear axle to semi float and I suspect they have fooled with the differential gear ratios, too, in the name of fuel economy. We shall see. Trying to get technical information from the dealers on this stuff is a lot like being water boarded.
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Old 22nd November 2008, 14:51   #15
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Default M&M NGCS Differential Ratios

Hi Dirty_Dan,

Let me give you some of the diff-ratios

2004 Maxx-Pickup with MDI3200 - 4.27:1 - Gearbox KMT90
2004 Bolero with MDI3200 - 4.27:1 - KMT90
2004 Bolero Camper MDI3200 - 4.88:1 - KMT90
2006 CL500 MDI3200 - 4.27:1 - KMT90
2006 Commander 650 MDI3200 - 3.73:1 - KMT90
2006 Savari MDI3200 - 4.27:1 - KMT90
2006 Bolero Camper MDI3200TC - 4.27:1 - Gearbox NGT520
2006 Bolero Camper MDI3200TC - 4.88:1 - Gearbox KMT90
2006 Bolero GLX MDI3200TC - 3.73:1 - NGT520
2006 Bolero XL MDI3200TC - 3.73:1 - NGT520
2006 Bolero DI DX MDI3200TC - 3.73:1 NGT520
2006 Maxx Festara MDI3200TC - 3.73:1 - NGT520
2006 Mahindra Pikup MDI3200TC - 4.27:1 - KMT90
2006 Marshal Royale MDI3200TC - 4.27:1 - NGT520
2006 Maxx Maxi-Truck MDI3200TC - 3.73:1 - KMT90

Regards,

Arka
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