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Old 11th December 2011, 19:00   #76
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

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Got the engine from the industrial My wife's zen helping My 550.


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FP Serviced.

"Heart Over Mind"  2001 MM550 XD - Rebuild-headpolished.jpg
Head welded the rusted area and Polished

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Pistons getting ready to work.

"Heart Over Mind"  2001 MM550 XD - Rebuild-engine-parts.jpg
Engine parts

"Heart Over Mind"  2001 MM550 XD - Rebuild-assembles.jpg
Assembling will be done by tomorrow.

Expense up to now :.

Parts - 22K
Industrial Work-7.5K
FP service -2K

Parts Changed :-

Piston - Goetze Piston
Rings - M&M
Sleeve- SLEEVE INDIA
Engine Bearings
Timing Chain
timing chain tensioner
rocker arm shaft
water pump Assembly
Radiator thermostat valve
Gasket (3Cut)
Accelerator Cable
silencer mounting kit.

- Sreejesh
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Old 11th December 2011, 19:35   #77
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Quote:
Originally Posted by sreejeshmp View Post
Attachment 854772
Head welded the rusted area and Polished
could you mark the area you 'welded' and say more about it... a welded head is not typically recommended by anyone, but many mechanics guarantee its welding strength...
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Old 11th December 2011, 20:38   #78
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Quote:
Originally Posted by svsantosh

could you mark the area you 'welded' and say more about it... a welded head is not typically recommended by anyone, but many mechanics guarantee its welding strength...
There are few rusted areas at the border of water flow path so I filled it by aluminum welding and polished .that will increase the gasket life.

- Sreejesh
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Old 24th December 2011, 22:43   #79
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Engine overhauling done.



"Heart Over Mind"  2001 MM550 XD - Rebuild-lsd.jpg

LSD in front .
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Old 25th December 2011, 21:26   #80
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Did a test to check the performance .



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Old 26th December 2011, 10:33   #81
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Hi Sreejesh,

A simpler test would be to jack up all 4 Wheels a let the vehicle idle in 4wd-Lo 1 st Gear.

All 4 Wheels should rotate in the same direction.

What about emergency spares, just in case the welded front axle snaps during an OTR?

Regards,

Arka
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Old 27th December 2011, 20:55   #82
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

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Originally Posted by ex670c View Post
Hi Sreejesh,

A simpler test would be to jack up all 4 Wheels a let the vehicle idle in 4wd-Lo 1 st Gear.

All 4 Wheels should rotate in the same direction.
Arka,
Yes,its very practical test for LSD differential. Once had the 550 roll forward while checking the speedometer with a new cable.
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Old 25th February 2012, 14:26   #83
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

After The engine rebuild The only thing makes sound in my jeep is the Gearbox so The rebuild starts.

"Heart Over Mind"  2001 MM550 XD - Rebuild-gearbox2.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-gearbox4.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-gearbox3.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-gearbox1.jpg



1,2&3 Gear need to replaced TC Counter shaft Needle bearing Everything except the Gearbox&TC case need to changed. But I am sure Once I did it in the proper way with proper Original Parts It worth doing it.
- Sreejesh
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Old 25th February 2012, 18:53   #84
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

before buying the parts do the math - it may be better to buy a used GB than spend on new Gears.
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Old 25th February 2012, 19:18   #85
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

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Originally Posted by svsantosh View Post
before buying the parts do the math - it may be better to buy a used GB than spend on new Gears.
Thanks Santhosh. But Buying a Used GB is again a problem because I don't know the condition of that Gearbox. So I Decided to rebuild it from the scratch Only taking the Best parts which is available to pick from the gearbox . I think It will be around 10-15K for the parts only.

- Sreejesh
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Old 1st March 2012, 19:50   #86
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Bought The Parts for the Gearbox.

MainShaft
1st Gear
2nd Gear
3rd Gear
All the Bearings
TC Counter Shaft,Bearing

and the pins,sir clips,etc.

Total Cost of the parts - 14600.00

Partes Need to Purchased - Clutch Cable , Original Clutch Cover assy for the Stepped flywheel.

"Heart Over Mind"  2001 MM550 XD - Rebuild-gear3.jpg
Changed parts of the Main Gearbox
"Heart Over Mind"  2001 MM550 XD - Rebuild-gear4.jpg
Complete New Assy.

"Heart Over Mind"  2001 MM550 XD - Rebuild-gear2.jpg
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Old 10th March 2012, 17:15   #87
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

"Heart Over Mind"  2001 MM550 XD - Rebuild-fly-wheel.jpg

Changed the Flywheel in to old bolero Xd3P Flywheel.

"Heart Over Mind"  2001 MM550 XD - Rebuild-geraboxxx5.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-geraboxxx3.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-releasebearing-hub.jpg

"Heart Over Mind"  2001 MM550 XD - Rebuild-fly-wheel1.jpg

Release bearing hub grinned to increase the Release bearing play to suit with the new fly wheel.

Old Gears..
Attached Thumbnails
"Heart Over Mind"  2001 MM550 XD - Rebuild-gearbox4.jpg  

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Old 12th March 2012, 12:39   #88
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Dear Sreejesh,

I would like appreciate your willpower and dedication in making your machine to its core perfection in factory specs.

Would love to see this with NGCS , OKBJ and a wider axle boss.. please do it.
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Old 12th March 2012, 23:18   #89
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

Quote:
Originally Posted by sreejeshmp View Post
Attachment 900567

Changed the Flywheel in to old bolero Xd3P Flywheel.

Old Gears..
Does that mean it is not the original stepped flywheel. Are you using the Same Pressureplate / Cover assembly ?
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Old 13th March 2012, 07:54   #90
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Default Re: "Heart Over Mind" 2001 MM550 XD - Rebuild

yes Boss. I changed to Bolero xd3p Old model Fly wheel. Its without the step but fittings like bolt pattern are same as the stepped fly wheel so I am using the same Pressure plate.
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