[nbk.0707]

Thank you all,
For your valuable comments, However Now my mind is completely jumbled up as, GTO San suggests a XD3P, Shubendra San suggests a DiTurbo and Dhanush San suggests a Scorpio Engine! So the rebuild plan will have to be redrawn.

Originally Posted by GTO

But the XDP 4.9 is so similar to the XD3P! Remember, using the best quality parts & labour at the start will save you many headaches later.

GTO san!

The XD3P was the PLAN! However changing a engine with only 10 BHP of power increase and as you say they both sound and act similar so that option is really on the back burner right now. One XD3P vehicle I want that is the 2006 and later MM550, Hopefully one day I'll be brave enough to buy one.

Originally Posted by Shubhendra

I am not sir.
...
Regards,
Shubhendra Singh

All points noted, Shubhendra San!

I have a visit scheduled in Delhi in the next week, would appreciate if you can share the contact details of your contact in Mayapuri.

I have seen three totaled M&M Pickups in the last week itself, all with the MDI with Inline Mico pump, Had any one of them been a rotary pump would have picked up the same, But I have purchased one BA-10 from a Bolero GLX, The engine was sold before I can even visit the scrapyard.

So the hunt is on and most probably I'll have the requisites in the next two weeks. The engine and GB is not posing a big problem now when I'm visiting the scrap dealers once a day, The biggest challenge as of now is the TC and the front axle tube.

Originally Posted by dhanushs

Hi, Sorry ...
Thats where expertise comes in, and reliability goes for a six.

Dhanush San,

One query I have which Scorpio engine should I look for CRDe or MHawk, as these engines are on the heavier side, what about the front heavy vehicle and the solid axle fouling with the belly pan. Though I have contacted every Insurance surveyor in my area for a Total loss vehicle for parting out, hopefully I will have a quote by Monday!

[Shubhendra]

Originally Posted by nbk.0707

The engine and GB is not posing a big problem now when I'm visiting the scrap dealers once a day, The biggest challenge as of now is the TC and the front axle tube.

One query I have which Scorpio engine should I look for CRDe or MHawk, as these engines are on the heavier side, what about the front heavy vehicle and the solid axle fouling with the belly pan.

The weight difference is around 125 kgs between XDP and Scorpio chain drive engine. You can compensate the same by adding long shock absorbers and one additional helper spring in front.
CRDe and MHawk engines are ECM controlled engines and you need to then get hold of wiring, sensors and ECM along with engine.

This is how chain drive engine looks like
Picture taken a week back when i was getting my engine rebuilt. My bolero is back on road two days back, will share my feedback once i complete 2000-3000 kms of road and offroad drive

Originally Posted by dhanushs

The best engine + gearbox combo I would recommend, would be a Scorpio engine and an NGT530R gearbox and a Borg Warner transfer case.Also, the engine IIRC comes with a PS pump, and fitting an AC shouldnt be a stress on this engine.

I am running on same setup and generally engine comes with alternator, PS pump and AC compressor. You have to pay extra if you want to buy turbo and intercooler along with engine. It may vary but this is how it works in Bombay, Kurla.


Regards,
Shubhendra Singh

[Maverick79]

Hi Jeepers,

Looking for wiring diagram for XD3P 2003 model wiring diagram.
Bought this through recent auction.

Thanks in advance.

Maverick79.

[dhanushs]

Originally Posted by Maverick79

Hi Jeepers,

Looking for wiring diagram for XD3P 2003 model wiring diagram.
Bought this through recent auction.

The engine doesn't need any wiring as such, apart from powering the FIP solenoid & heater plugs.

Rest of the Jeep's wiring, you can get it done from any roadside auto electrician.

[Faizal]

Hello everybody,

I am new at your forum and know you will guide me when I make mistakes. I am from Suriname South America, hopefully you know my country.

I own a Mahindra Scorpio double cabin pickup, which I use off-road whenever I am free.

I have a big problem with the transmission (hopefully I am at the right thread, I can not find one with "scorpio and gearbox/transmission"). The dealer in my country left us in the cold, they are not selling Mahindra's anymore.

BA10/NGT530 V1 is labelled on the gearbox. Can I replace it with a NGT530R V4? Mahindra part nr.:0703AAD04110N

There are no parts in Suriname available to repair the gearbox. I will have to import it from India.

Do you have other suggestions?

Your forum already helped me alot to maintain my pickup.

Best regards,

Faizal

[dhanushs]

Originally Posted by Faizal

BA10/NGT530 V1 is labelled on the gearbox. Can I replace it with a NGT530R V4? Mahindra part nr.:0703AAD04110N

Yes you can replace the gearbox to NGT530R. It’s the newer version. Do you have the electric shift TC? If so, change to manual shift from the Thar CRDe sold in India. Saying this, since you are anyhow importing the GB.

[Faizal]

Originally Posted by dhanushs

Yes you can replace the gearbox to NGT530R. It’s the newer version. Do you have the electric shift TC? If so, change to manual shift from the Thar CRDe sold in India. Saying this, since you are anyhow importing the GB.

Thanks dhanushs,

I appreciate your help. I was not sure if the input shaft would match.

I have the electric shift TC, it has the worst control system imaginable. I bypassed the controls and wired the switch motor directly. Works like a charm, but for now I can only switch between 2H and 4L. I am working on to get 4H.

For now I can only purchase a complete transmission (with bell housing) at the cost of "a hand and a foot". Does anybody have suggestions where I can purchase it without the bell housing (and where they can ship outside India) so I can only "loose my foot". It will reduce the freight costs.

Best Regards,

Faizal

[Rahul Rao]

Originally Posted by Faizal

BA10/NGT530 V1 is labelled on the gearbox. Can I replace it with a NGT530R V4? Mahindra part nr.:0703AAD04110N

BA10 and NGT53 are different transmissions that share a housing. The part no is housing part no.

https://www.team-bhp.com/forum/4x4-t...ml#post2422797 (Need advice:MM 550 BA 10 : 4x4 gear box direct Shift.)
This thread will advice you on overhaul or modification of your transmission.
if you know a competent mechanic who can dismantle the transmission do so, and procure only the required parts from India.


Rahul

[Faizal]

Originally Posted by Rahul Rao

BA10 and NGT53 are different transmissions that share a housing. The part no is housing part no.

https://www.team-bhp.com/forum/4x4-t...ml#post2422797 (Need advice:MM 550 BA 10 : 4x4 gear box direct Shift.)
This thread will advice you on overhaul or modification of your transmission.
if you know a competent mechanic who can dismantle the transmission do so, and procure only the required parts from India.


Rahul

I am a little confused. I attached a photo of the label on the gearbox.

Best Regards,

Faizal

[baradus1210]

A history question

Why did Mahindra opt for a French diesel engine, there were options but they opted for different models of the Peugeot diesel engines and likewise why a Korean KMT 90 gearbox. Can the gurus please help enlighten on this history

[jeepster]

XDP 4.90 Diesel Engine

Mahindra’s search for a modern diesel engine ended with a technical collaboration with Peugeot (France) to manufacture state of the art & modern diesel engines and gearboxes. The XDP 4.90 was the first Diesel engine out of this collaboration.

• Plant – Ghatkopar (Bombay), Igatpuri
• Production – 1979 – 2005
• Engine Model – XDP 4.90

Engine specifications –

• Type – Indirect Injection Diesel (IDI)
• No of cylinders – 4
• Capacity – 2112 cc
• Fuel Delivery – DPA Rotary pump with Pintle injectors
• Governor – Mechanical , All speed Governor
• Power – 62 hp at 4500 rpm
• Torque – 12.3 kg-m at 2000 rpm

The XDP 4.90 Diesel Engine was one of the modern high speed diesel engine of the 70s and 80s. It had many unique features –

• XDP 4.90 was an over-square design with the stroke (83mm) being lower than the cylinder bore (90 mm).
• It was the first Diesel engine in India fitted with a Rotary Fuel Injection Pump. The CAV design rotary pump was supplied by Roto-Diesel (France), Con-Diesel (Spain) and later Lucas-TVS (India)
• It had an Aluminum cylinder head.
• The combustion system was of swirl chamber design and fitted with Ricardo Comet V swirl Chamber.
• Catridge type oil filters and fuel filters were also new concepts at that time.
• It also had a troublesome design of a rope oil seal at the crankshaft rear end.

In after-sales service, the entire universe of dealer technicians had to be re-trained to handle the new way of fuel pump timing setting, anti-stall setting and handling Aluminium cylinder heads during engine repairs.
Author’s note – This new engine was like a breath of fresh air and spawned a plethora of new vehicle models – NC665DP, CJ500DP, CJ540DP, NC640DP, CJ640DP, MM540DP, FJ460DP, Armada – the DP standing for “Diesel Peugeot”. This engine was discontinued in 2005, when India moved to BS3 emission norms.

XD3P Diesel Engine

XD3P was the second engine to come out of the collaboration with Peugeot. This engine was much more refined as well as had more power output.

• Plant – Igatpuri
• Production – 1994 – 2010
• Engine Model – XD3P

Engine specifications –

• Type – Indirect Injection Diesel (IDI)
• No of cylinders – 4
• Capacity – 2498 cc
• Fuel Delivery – DPC Rotary pump with Pintle injectors
• Governor – Mechanical , Mini-Max Governor
• Power – 76 hp at 4500 rpm
• Torque – 15.3 kg-m at 2000 rpm

The engine was used to power most of the new models like Armada Grand, Voyager, MM540 XDB, MM540 XD-Army and the Bolero.

KMT90 Gearbox

With the engines becoming bigger and also torquey due to dieselisation, Mahindra needed a replacement for its old and ageing Warner T90 3-speed transmission. The T90 transmission has done its duty on Mahindra vehicles for more than 35 years, by this time. The T90 transmission continued for another 15 years along with this new transmission.
The higher speed range of the modern high speed diesels required atleast 4 gear ratios to span the speed range and provide good drive-ability. The KMT90, 4-speed transmission from Kia (Korea) was brought in to fill the gap. The KMT90 design was localised and manufactured in-house.

• Plant – Kandivli (Bombay)
• Production – 1981 to 2015
• Model – KMT90 / MS90

This gear box had sliding spur gear as the first gear and “blocking ring type” synchronisers in the other three gears. The vehicle needs to be brought to a complete standstill when shifting in to the first gear.
A design upgrade of converting the first sliding gear to a synchromesh was done in 1998 to meet customer requirements of specific markets. This gear box was known as the MS90.
Author’s note – The KMT90 gearbox stopped production in 2015 as it could not meet the pass-by noise regulations.

Spicer T18 Transfer Case

Spicer supplied T18 Transfer Case to Willys. This transfer case was of 2-speed design and had a high gear (1 : 1) and a low gear (2.46 : 1) ratio. It is still getting manufactured at Mahindra plants and are fitted in 4WD versions of the Mahindra Pikup, Bolero Maxitruck, Bolero Camper as well as the Roxor in the US.

• Plant(s) – [COLOR=#c4493f]Mazagaon, Ghatkopar, Kandivali[/COLOR]
• Production – 1949 till now*
• Model – Spicer T18

The interlock system in the transfer case does not allow the possibility of a 2WD Low mode. A small interlock plunger between the two shift rails inhibits this operation.
The original design of the T18 transfer case remains same even today except the shifting patterns have changed. Original shifting pattern had 2-levers which then moved to a single lever U-Shift pattern and finally to a single lever straight line shift pattern



In April 2023, a major redesign was carried out to convert the low gear from sliding mesh to constant mesh. This was the first redesign in 74 years.

Borg-Warner 45-55 Transfer Box

The Spicer T18 Transfer Box has done its duty on Mahindra 4WD vehicles for 50+ years. The robust but crude design, especially its shift efforts, was not suited for the modern automobiles of the 90s.
Mahindra narrowed down on the Borg-Warner Transfer case for use in its newer models.

• Plant – Divgi-Warner (Pune)
• Procured – 1998 to now
• Model – 4555

The BW transfer box was of 2- speed design with high ratio of 1:1 and low ratio of 2.48:1. The all Aluminum housing transfer box had a chain drive with upper disconnect and was one of the easiest transmissions to repair.
The transfer box was available in both mechanical and electric shift options and had an interesting “blink code” dignostic protocol.
Gear Ratios – 2.48 & 1
The BW 45-55 transfer box was fitted on –

• Armada Grand
• Scorpio
• Bolero Invader GLX
• Scorpio CRDe
• Scorpio Getaway
• Scorpio mHawk
• Scorpio Automatic
• Thar CRDe
• Mahindra Pikup (2017)
• Mahindra Pikup (2019)
• Thar [2020]
• Scorpio-N
• Thar ROXX
  

Source: https://mahindramuseum.in/

[baradus1210]

The xdp 4.90 was used in the diesel version of the Peugeot 504 - a model which was extremely popular especially in Africa. A question which comes to mind is why did Mahindra select a French engine - was it because the French Franc was more favourable as currency in the pre Euro days, they could have selected a Japanese engine as Mitsubishi used to manufacture Jeeps in Japan. Bajaj around the same time brought in the Mercedes Om616 possibly because of the Hanomag/Mercedes connection and their plan to bring in the Sprinter.

[dhanushs]

Originally Posted by baradus1210

The xdp 4.90 was used in the diesel version of the Peugeot 504 - a model which was extremely popular especially in Africa. A question which comes to mind is why did Mahindra select a French engine - was it because the French Franc was more favourable as currency in the pre Euro days, they could have selected a Japanese engine as Mitsubishi used to manufacture Jeeps in Japan. Bajaj around the same time brought in the Mercedes Om616 possibly because of the Hanomag/Mercedes connection and their plan to bring in the Sprinter.

There are multiple variables from an OEM point of view in selecting hardware, than just the functionality part of it. Finances, Legal frame work, Development, Cost and more.. Sometime you find it strange to see an OEM going with a certain supplier when it had made total sense for the OEM to do it.

[boxwrench]

Hello Jeep enthusiasts,

I am looking to convert a CJ500D with an IH B275 engine to a DI. I have a T90-T18 transfer case combo and i would like to retain it(strict budgetary constraints). Based in these requirements i suppose an MDI2500 is a direct fit(let me know if otherwise). I request your help in sourcing a good DI engine. I am located in Coimbatore and if anyone has a good experience sourcing an engine anywhere nearby(kerela is not out of bounds) please share it with me. Thank you in advance.

[boxwrench]

Originally Posted by boxwrench

Hello Jeep enthusiasts,

I am looking to convert a CJ500D with an IH B275 engine to a DI. I have a T90-T18 transfer case combo and i would like to retain it(strict budgetary constraints). Based in these requirements i suppose an MDI2500 is a direct fit(let me know if otherwise). I request your help in sourcing a good DI engine. I am located in Coimbatore and if anyone has a good experience sourcing an engine anywhere nearby(kerela is not out of bounds) please share it with me. Thank you in advance.

Hello again,

Update on the engine purchase. I was able to source a good DI engine from a mechanic here in Pollachi. It was fitted in an MM540 and after starting and moving the vehicle I decided it was a good deal and purchased it. The mechanic purchased my old engine and dismantled the DI engine from the MM540 and gave it to me. I had to pay an additional 23000 after giving my old engine(may be i overpaid but it saved me a lot of travel and time). The market price for an MDI engine in my locality is 40k(you must give ur old engine). Just an update for people who are interested.