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Old 4th February 2008, 21:43   #1
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Default Installing a 5-Speed Tranny on an MM540/MM550

Question for the Jeep Experts out there.

Is it possible to install a BA10/NGT20/NGT30 Transmission to an MM540/MM550 and still keep the existing 4x4 Transfer case?

I know that when Jeep sold the MM550 XDB they used to offer it with the BA10 gear box but I am not sure if they offered it in four wheel drive.
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Old 5th February 2008, 14:45   #2
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Hi 4x4addict,

Why not just pick up a 5 speed 4x4 transfer case? There are some available in the used market. If the dealer allows you to exchange, the difference will be marginal.
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Old 5th February 2008, 19:23   #3
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Hi GTO,

Just wanted to confirm that Mahindra did make a 5speed with a 4x4 transfer case. I get different opinions about this. Many claim that the 4x4 only came with the 4 speed and I will have to fabricate a bell housing to install a five speed. I wanted to know if I could buy one from the dealer off-the shelf and install it to the XDP engine.
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Old 5th February 2008, 19:32   #4
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yes ..M7M made 4x4 with 5 speeder.... it was on the armada grand...I don't about themm550...but the engine gear box is the same on both so it should be possible..
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Old 5th February 2008, 19:40   #5
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Possible.But, sourcing it is everything.
Quote:
and I will have to fabricate a bell housing
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Old 6th February 2008, 10:01   #6
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The MM540 and the MM550 had different gearboxes. I don't think Mahindra ever made a 4wd transfer case built into the gearbos on the BA10. When I recently converted a 540 to a XD3P engine, I changed the gearbox too. The BA10 for 4wd, comes with a flange fitting on the rear part of the housing, to fit the transfer case. The gearbox alone cost 42K. The transfer case had to be sourced from chennai. The transfer case for the BA10 is very, very difficult to come by.

Last edited by jyobeb : 6th February 2008 at 10:03.
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Old 6th February 2008, 20:35   #7
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Hi 4x4addict,

I moved this thread to the Modifications and accessories section where it is more suited.
Technical stuff would be more suited to general discussions/theories/questions that are more universal.

cya
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Old 18th February 2008, 22:37   #8
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Hi jyobeb,

Where did you source the XD3P and BA10 4wheel gear box from? I'd like to do the same to my MM540.
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Old 18th February 2008, 22:39   #9
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Quote:
Originally Posted by jyobeb View Post
The BA10 for 4wd, comes with a flange fitting on the rear part of the housing, to fit the transfer case.
Does the flange fitting come on all BA10s or is there a four wheel version. Is the transfer case different from the standard one used on all jeeps or specific to BA10?
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Old 18th February 2008, 23:41   #10
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The BA10 4wd gearbox was sourced from an erswhile Mahindra dealer in Madurai called Kodai automobiles and the XD3P engine from Pudupet in Chennai. I have friend there called Jamsheed. His mobile is 09840387776. He does not speak English very well, but is a good guy with a lot of good stuff. Will not cheat you and is a treasure source of engines, gearboxes, parts and stuff. Tell him that "John" referred you to him.
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Old 18th February 2008, 23:41   #11
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Quote:
Originally Posted by 4x4addict View Post
Does the flange fitting come on all BA10s or is there a four wheel version. Is the transfer case different from the standard one used on all jeeps or specific to BA10?
The transfer case is totally different from that in the MM540 with the 4 speed gearbox.In fact it is similar to the ones used in the Safari and the scorpio. In the 4wd BA10, only the rear flange is different. I have seen mahindra jeeps with the regular 2 lever transfer case, a single lever transfer case as well as the "shift on the fly", electronic transfer case

Last edited by jyobeb : 18th February 2008 at 23:49.
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Old 19th February 2008, 07:51   #12
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Thanks john. I will contact Jamsheed.

I am still on the lookout for a post 2004 MM540/550 XDB. Besides the more powerful engine and 5-speed gear box it comes with a host of other chasis improvements. I have left word with a bunch of vehicle brokers in Gudalur, Ooty, Kumily area which tend to have a lot of jeeps. But a newer 540 with the XD3 engine is hard to find. Anyway, I want to go ahead with the conversion to XD3P engine and BA10 only if I am not able to find an original 2004 plus model.
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Old 20th February 2008, 14:43   #13
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I spoke to jamsheed and he said that the 5 Speed BA10 with 4x4 is impossible to find. He recently tried to source one for another customer.

Anyway i saw a 4x4 Armada Grand in Bangalore and chased down the driver and got the owners number. I am negotiating a price for it and if it works out I will buy it and transfer the power train over to my MM540 and then junk the Armada. The four-wheel drive unit is however a Borg Warner Electric unit.

Do you know if I can adapt my existing transfer case from the MM540 to the 4x4 BA10 gear box?
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