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Old 18th December 2010, 09:02   #1
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Default MM540 2wd to MM540 4wd and Restoration

Dear Friends,
I am starting a new thread of converting my Friend Mr Roys recently 1997 model MM540 2wd to 4wd in Coimbatore.The vehicle was transported in a Truck to South India Motors.Intial Pictures below.More to follow.
Rajith
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Old 18th December 2010, 09:05   #2
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Default Re: MM540 2wd to MM540 4wd and Restoration

pictures missed in the first post , so added below and millions to follow.
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Old 18th December 2010, 09:33   #3
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Default Re: MM540 2wd to MM540 4wd and Restoration

congrats Rajith !!

have you collected the necessary parts?
  • which Gearbox? 4+1 or 5+1?
  • which Transfer case? T18 or Borg Warner 1350 manual?
  • which front axle are you planning to use? 57" OKBJ or 51" closed knuckle?
  • rear full floating axle? 51" FFRA or 53" FFRA or 59" FFRA?
  • any plans for LSD's or differential locker?
  • which differential ratio? 4.88 or 5.38?
also please share the prices of following parts.
  • Front axle
  • Rear axle
  • Transfer case
best of luck for the project.

rgds,
Nikhil

EDIT: i assume you are retaining XDP4.9 engine.

Last edited by jeepster : 18th December 2010 at 09:37.
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Old 19th December 2010, 21:15   #4
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Default Re: MM540 2wd to MM540 4wd and Restoration

Quote:
Originally Posted by jeepster View Post
congrats Rajith !!

Answered below sir

have you collected the necessary parts?
  • which Gearbox? 4+1 or 5+1?
4+1 Gear box
  • which Transfer case? T18 or Borg Warner 1350 manual?
T18
  • which front axle are you planning to use? 57" OKBJ or 51" closed knuckle?
MM 550
  • rear full floating axle? 51" FFRA or 53" FFRA or 59" FFRA?
SFRA MM 540
  • any plans for LSD's or differential locker?
Yes
  • which differential ratio? 4.88 or 5.38?
4.88
also please share the prices of following parts.
  • Front axle
  • Rear axle
  • Transfer case
best of luck for the project.

rgds,
Nikhil

EDIT: i assume you are retaining XDP4.9 engine.
XDP4.9 engine retained
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Old 19th December 2010, 21:34   #5
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Default Re: MM540 2wd to MM540 4wd and Restoration

Full Body has been Rusted, Need 100% scraping right from Chasis to Body.We have brought full MM 550 Front Differential set, Rear Differential Tubes and the Transfer case,MCBRT sterring Box,Disc brakes,New accelerator pedals,Clutch and Breaks along with latest type rear doors,Defence lights,D hooks etc from Auction Market in kerala , Muvthupuzha.Driven down from Bangalore in Bolero with all seats removed except driver and co driver, stuffed the spares, unloaded at coimbatore and retunded back , all in 48Hrs.
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Old 19th December 2010, 21:43   #6
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Default Re: MM540 2wd to MM540 4wd and Restoration

More pictures updated belowWork is progressing in full speed with full blessing of jeep go.Body removed,Chasis fully scraped,Front/rear differentials ready, Gear box assembled.
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Old 19th December 2010, 21:53   #7
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Default Re: MM540 2wd to MM540 4wd and Restoration

Ready to Fit spares uploaded below.chasis is primer painted after fixing differentials and gear box with 4 wheels-pics expected soon
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MM540 2wd to MM540 4wd and Restoration-phpvj0hxiam.jpg  

MM540 2wd to MM540 4wd and Restoration-phpgcpgwaam.jpg  

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Old 20th December 2010, 07:31   #8
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Default Re: MM540 2wd to MM540 4wd and Restoration

the work is in full swing.

why are you using the narrow 51" axles? any specific reason?


BTW dose the axles shown in following picture are for sale?
if yes then please inquire about the following wide track axles & their price?
  • 57" OKBJ (used 4x4 bolero, maxx)
  • 59" FFRA (4x2 maxx)

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Old 20th December 2010, 08:52   #9
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Default Re: MM540 2wd to MM540 4wd and Restoration

Hi Jeepster,

We are retaining same gear box with additional T case ,differential pumkin changes from centre to right , so taken a Rt oriented empty tube/pumpkin and replaced the crown/pinion/axle set in new one.

Pics shows the scrap market stock of differentials when we picked up from kerala.

Planning put white color with a combination of mat olive green under chassis color, Army Rims fitted with Maxix MT tyres
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Old 20th December 2010, 09:04   #10
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Default Re: MM540 2wd to MM540 4wd and Restoration

Rajith, All the best for this new killer 540.

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Can you please share the price details of this D Hooks and the rear Hook with hook plate ? is it easily available there ? I really like to pick it for my new jeep.

can anyone please explain the use of that spring loaded thing on the hook plate ?
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Old 20th December 2010, 10:38   #11
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Default Re: MM540 2wd to MM540 4wd and Restoration

hi sree,
Alltogether we paid 40k, it was mad buy deal.Dont have individual prices.
lot of similar pcs are there, u can pick.
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Old 20th December 2010, 10:47   #12
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Default Re: MM540 2wd to MM540 4wd and Restoration

Quote:
can anyone please explain the use of that spring loaded thing on the hook plate ?
I have that thingie in my Jeep too. I think its power supply for radio/trailer lights or maybe even a canon.

All the best on your build Rajith
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Old 20th December 2010, 11:03   #13
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Default Winch Plate

Hi Rajith,

Please fabricate a Winch Plate before fitting the MRCBT Steering Box.

This will serve 2 functions.

1) The NGCS has a Tubular Cross-Member, in front of the Steering Box for reinforcement. The Winch Plate can serve this purpose also.

With out this plate when the steering is actuated you can feel & see the front section of the chassis twist, this will put additional strain on the steering box & mounts.

http://www.team-bhp.com/forum/4x4-ve...ml#post1158663 (My MM540XD upgrade)

2) If the Winch Plate in not fitted now, later on it will become very difficult to fit the winch plate.

Regards,

Arka
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Old 23rd December 2010, 12:36   #14
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Default Re: MM540 2wd to MM540 4wd and Restoration

Thanks Arka for providing the MM540 Winch plate specs.
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Old 5th January 2011, 09:48   #15
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Angry Re: MM540 2wd to MM540 4wd and Restoration

Dear Friends,
Absense of Tinker has slowed down the body shell repair from last 2 weeks.Now restarted.I will be posting more photos and technical upgradations in detail, shortly.
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