[svsantosh]

Thanks a lot Beboy...!

Screw the Cable, I am doing this

[svsantosh]

Got the AG back from mechs place.

1) Radiator fully rebuilt, was clogged up badly over the years. Also found it is a 3 core one, not the 4 core one as on my CJ. Cost of rebuild - 500rs (no leaks and overheating after a long TD)

2) All 4 hubs greased, all bearings ok, changed oil seals.

3) Front Knuckles/Kingpin overhauled, as said in prev page - the top kingpin had a plastic bush and bottom was a regular bearing. I did a mod here - From the time I got the AG I felt the PS over-servoed and too vague for my liking. So got rid of the bottom kingpin bearing and went for a 'unipak brand' brass bush. So I dont have any kingpin bearings now, and after a 50Km Test drive over highway, rural roads, slight offroad I can say the power-steering feels perfect now, need the elbow a bit but not too much, and just enough servo to feel at ease!!

4) Alternator opened up and rebuilt, the leak was not from the oil seal still got a new one at 220, labor 180 - 400Rs here.

4 oil seals
1 knuckle kit
2 brass kingpin bushes
^^ - 580Rs

2 knuckles and 4 hubs took around 2Kilos grease, I had them in stock, so dont recollect the prices. Approx 150rs/Kg

edit - 120Rs for a new 1-foot hydraulic hose 10mm dia - which returns engine oil from ALT to engine block.

Labor for 4 wheel hub grease, radiator removal refitting, 2 knuckle rebuild, 1 alternator removal-refit = 1000Rs (asked more, but i gave only that much!!)

Next month oil change and tappet tuning due...

[svsantosh]

Originally Posted by svsantosh

Thanks a lot Beboy...!

Screw the Cable, I am doing this

Done This time again on front disc's like the CJ... parts are slightly expensive this time, all included came upto nearly 1000

[svsantosh]

The OE rear was supposed to have 5 and front shd be 6. I read this from Spikey's reply in Rolling AG of Suresh Stephen... Last post...

http://www.team-bhp.com/forum/4x4-te...ada-grand.html



The pic above was my rear set, had 7 leafs and was pretty hard, and more thanks to the Sand grips! Got 2 removed and said the recamber guy to max the height. All 4 sets with misc parts costed me 350Rs for parts and 1500 for Labor. Took about half a day...

Post the recamber, this is the stance.

[Sabareesh]

Originally Posted by svsantosh

Post the recamber, this is the stance.

Santosh,

I don't know whether its my eyes playing tricks but I see that the rear is sitting a tad higher than the front end. Any particular reason for this ? Was the front set recambered as well ?

[svsantosh]

Originally Posted by Sabareesh

Santosh,

I don't know whether its my eyes playing tricks but I see that the rear is sitting a tad higher than the front end. Any particular reason for this ? Was the front set recambered as well ?

Usually thats how an all-4 leaf vehicle is set by the camber guy. They say its for load, etc etc in rear, but it doesnt matter. As long as it is soft in rear, and front doesnt cause a axle wrap you are good...

oh, i almost forgot - the front axle wrap I had during purchase (under sudden braking) has vanished after this recamber work. I guess my mech was right after all, it was too flattened out when I had purchased it.

[svsantosh]

Bolted on existing CJ's winch plate on a 2x2 bolt pattern directly on the long members of the AG. All credits to Mohan.













Only issue was with front grill which I didnt like anyways, so it got the treatment!! Oh, and the winch works fine

[svsantosh]

Found a good ramp at Mohans home to test the articulation of the NGCS. Here are 2 pics for your reference!

I was stupid enough not to engage 4wd and while reversing had no traction in rear right and went in a further good 3-5 inches!! Then got down, FWH+Shiftster and crawled out

[svsantosh]

Lots of small updates...

After Recambering of all 4 leaf packs



Got the diff guards installed



Attempted and got a body lift using balatta packing (Nylon bush idea failed for wrong design execution)







Also made a custom rear tow hook/dshackle receiver







Grill lifted but radiator in same place (OE) for water pump reason



Rear plate with hook



One body bed was cut and causing LOTS of confusing symptoms and we went to extent of nearly opening up steering system!!



After lift...



Front view after lift



Then decided to ditch the DC Grill and go MM Way!!



Tinker chiseling away the spot welded plate



Blind!!



new lights!



Rims looked out of place and did a can spray job DIY (all black now)



Painting the front grill



Masked and drying...



final outcome...

[sriny_blr]

That looks a monster in front view with all those additional lights....

Interesting AG comes without hand brake??? or am I missing something...

Reminds me to adding my list to get the simple DIY handbrake. I like that...

[svsantosh]

AG came with a HB, but tooooo complicated to change the cable once its due for replacement - so ditched it!

[madhkris]

Nice body lift, front grill colour and Rear tow hook Santosh. I have a few questions.
Does the body lift alter the steering geometry?
How is the ride quality?
Does it help in increasing the articulation?
Since the radiator sits a bit below, does this cause an issue later?
Do you need a K member to place the tow hook or can be done even on a 540?

[svsantosh]

Originally Posted by madhkris

Does the body lift alter the steering geometry?

How is the ride quality?

Does it help in increasing the articulation?

Since the radiator sits a bit below, does this cause an issue later?

Do you need a K member to place the tow hook or can be done even on a 540?

1) Strictly speaking YES - but not much a disaster in a MRCBT Vs your current setup

2) hmm, since mine earlier OE setup was in shambles, now its better with newer beds/balatta pieces, so cant really compare - but again, the COG goes up and rolling is more pronounced

3) Hmm - NO, tyres wont get damaged inside the front fender (31+" tyres)

4) Radiator is still in OE position, only the AC condensor has gone up a inch alongwith the grill, no issues in AC perf...

5) AG didnt have a tow hook, thats why had to beg for the plate from my neighbour

[Sutripta]

Originally Posted by madhkris

Does the body lift alter the steering geometry?

Originally Posted by svsantosh

1) Strictly speaking YES - but not much a disaster in a MRCBT Vs your current setup

Hi,
The question is the routing/ angle of the steering column/ shaft, rather than the type of steering box.

Regards
Sutripta

[svsantosh]

Originally Posted by Sutripta

Hi,
The question is the routing/ angle of the steering column/ shaft, rather than the type of steering box.

Regards
Sutripta

yes Dada, but I was contemplating docs next question and discouraged him attempting in his 540... mrcbt forgives you in this mod while a old steering box in 540 won't let you stretch the rod out of its milling by more than qtr, half an inch...