My new Bolero Di 4x4 and its Mods

The Wolf · 28th April 2012, 11:05

Nice mods... I like the focus you have towards keeping your machine simple yet functional. I am a strong believer of a fact that the Bolero 4x4 is still a very less understood/explored vehicle from the offroad stand point purely due to people's inability to accept it as a serious offroader. Its a mindset issue I reckon.

The only loop hole as i see it is the diff ratio, a 4.27 (or more) should make it extremely capable along side sensible mods like that of yours. I in my experience have seen Mahindra GE mgmt team use Bolero's with full occupancy like no mans business during their recce's and offroad events. Was infact baffled to see one of the marshall's vehicles beat down obstacles like they never existed during the Chikkamagalur G.Escape (yr 2010 Im guessing) which was one of their better escapades due to a respectable selection of the terrain and season meant for 4x4s only. I was following this vehicle in my '87 540 with 5.32ratio.

Good job, keep it going...

offroad_maniac · 8th May 2012, 23:31

Quote:

Originally Posted by The Wolf

The only loop hole as i see it is the diff ratio, a 4.27 (or more) should make it extremely capable along side sensible mods like that of yours. I in my experience have seen Mahindra GE mgmt team use Bolero's with full occupancy like no mans business during their recce's and offroad events. Was infact baffled to see one of the marshall's vehicles beat down obstacles like they never existed

As Vinod_Nookala has mentioned in some other post that these M&M recovery Boleros are equipped with 4.88 ratio & some body lift as well. Great potential if modded sensibly like done here. Can be best expedition vehicle with security of closed doors & 4wd option in this price range. I really hope they should release LX models for normal public a well.

coloneljasi · 17th August 2012, 11:00

@ vak: Sorry to bump an old thread, but I think I saw your Bolero going towards Thrissur yesterday evening. I drove past in the opposite direction on my way back on the SH 69 to Calicut, near Lulu International.

Have you done any further changes to your ride? Your Bolero looks like it means business!

drbones · 17th August 2012, 11:53

vak, good write up of your long term bolero 4x4.

But bolero with out power steering is tough task daily, Brave decision this shows your passon for a 4x4.

I think gypsy is good with out power steering, but no diesel in gypsy.

I have enquired about bolero 4x4, but the dealer refuses to accept that bolero comes with 4x4. God save mahindra from the dealers.

dealers are the culprits who are killing 4x4 s in india.

offroad_maniac · 17th August 2012, 13:02

Quote:

Originally Posted by drbones

I have enquired about bolero 4x4, but the dealer refuses to accept that bolero comes with 4x4. God save mahindra from the dealers.

dealers are the culprits who are killing 4x4 s in india.

I think this is because Mahindra has now dicontinued the SLX 4x4 model.
The remaining model DI 4wd is either have very long waiting period or not easily available to public, as its for govt. use (as per sime dealers).

Now there was this news of New Bolero ZLX in 4wd variant, but as of now its not listed over site. Not sure if dealers are accepting booking. Anyways it will be over 8-9 lakh on road.

offroad_maniac · 18th August 2012, 20:24

One more thing for the gurus.
Can we fit a gear lock on a 4wd Boleros? As the base of main gear lever and 4wd selector is quite close to each other. Dont trust dealers unless its done before.

Also how safe is it to use the standard hub locks and continue to drive in 2wd mode?

DirtyDan · 19th August 2012, 13:27

Quote:

Originally Posted by offroad_maniac

One more thing for the gurus.
Can we fit a gear lock on a 4wd Boleros? As the base of main gear lever and 4wd selector is quite close to each other. Dont trust dealers unless its done before.

Also how safe is it to use the standard hub locks and continue to drive in 2wd mode?

It's safe. Safety is not the issue. You may notice no difference in handling at all between 2wd locked and free if your alignment is correct and your front end is healthy. Many experienced drivers will notice the small difference, however.

If you don't install hub locks there will be rotation of the front wheel drive components when you are in 2 wheel mode. This will result in friction which will slightly shorten the life of your front wheel components over much time and slightly lower your fuel average. I have hub locks. When I know I might encounter a situation where I need 4 wheel drive I lock the hubs well in advance of the situation. E.g. that morning or kilometers before I get into the muck. The wear especially at low speeds is very small and not a big issue. Handling is a non-issue.

offroad_maniac · 19th August 2012, 15:34

Quote:

Originally Posted by DirtyDan

It's safe. Safety is not the issue. You may notice no difference in handling at all between 2wd locked and free if your alignment is correct and your front end is healthy. Many experienced drivers will notice the small difference, however.

If you don't install hub locks there will be rotation of the front wheel drive components when you are in 2 wheel mode. This will result in friction which will slightly shorten the life of your front wheel components over much time and slightly lower your fuel average. I have hub locks. When I know I might encounter a situation where I need 4 wheel drive I lock the hubs well in advance of the situation. E.g. that morning or kilometers before I get into the muck. The wear especially at low speeds is very small and not a big issue. Handling is a non-issue.

Thanks for the detailed answer

How about fitting of gear lock in a 4wd vehicle? Will it fit properly considering the 4wd selector nearby.

offroad_maniac · 22nd August 2012, 12:36

Quote:

Originally Posted by offroad_maniac

How about fitting of gear lock in a 4wd vehicle?
Will it fit properly considering the 4wd selector nearby.

Dear all,
Please help.

svsantosh · 22nd August 2012, 13:01

how about fitting it from co-driver's side? Some juggad is needed, but see the space/viability... some pics of product may help.

starter · 22nd August 2012, 13:11

But how does it help Santosh/Offroad_Maniac? Inspite of the gear lock, one can still use the 4wd selector and bring the car to neutral isn't it?

offroad_maniac · 24th August 2012, 10:29

Quote:

Originally Posted by starter

But how does it help Santosh/Offroad_Maniac? Inspite of the gear lock, one can still use the 4wd selector and bring the car to neutral isn't it?

Ohh. Is it the case? But even if it goes in neutral, they (thieves) will have to push it all the way which will be a hard task.
I have seen picture of gear lck fitted in SLX model (sriku's) but not sure , if 4wd lever when pushed to Low will interfere with lock or not.
If it can be fitted from co-driver side then nothing like it, but then we may have to lock it in 2nd instead of Reverse?

joethomasv · 24th October 2012, 09:42

Hi Vak,

I'm trying to fix an ac in my Thar Di. Can you tell me which pulley you used for the install?

4x4addict · 24th October 2012, 09:56

Quote:

Originally Posted by joethomasv

Hi Vak,

I'm trying to fix an ac in my Thar Di. Can you tell me which pulley you used for the install?

Hi Joe, If you are not planning power steering you can go for the OEM two slot pulley from the Bolero DI. If you are planning on power steering, then you need to source the 3 slot pulley which is not easily available. Some good AC mechanics can make the pulleys for you at a lathe.

See my team-bhp DI Thar thread, I have mentioned the complications of putting AC in DI Thar.

joethomasv · 24th October 2012, 10:28

Thanks for the quick reply. I have your Thar DI thread in my boomarks. The blower is already installed so there is no going back. I might have to move the passenger seat a few inches back though.
The AC guy has sent the pulley to Kovai but I prefer an OEM one. I'll try to source the 2 slot pulley from Cochin.

28th April 2012, 11:05	#31
The Wolf Senior - BHPian Join Date: Jan 2005 Location: Bangalore Posts: 1,119 Thanked: 75 Times	Re: My new Bolero Di 4x4 and its Mods Nice mods... I like the focus you have towards keeping your machine simple yet functional. I am a strong believer of a fact that the Bolero 4x4 is still a very less understood/explored vehicle from the offroad stand point purely due to people's inability to accept it as a serious offroader. Its a mindset issue I reckon. The only loop hole as i see it is the diff ratio, a 4.27 (or more) should make it extremely capable along side sensible mods like that of yours. I in my experience have seen Mahindra GE mgmt team use Bolero's with full occupancy like no mans business during their recce's and offroad events. Was infact baffled to see one of the marshall's vehicles beat down obstacles like they never existed during the Chikkamagalur G.Escape (yr 2010 Im guessing) which was one of their better escapades due to a respectable selection of the terrain and season meant for 4x4s only. I was following this vehicle in my '87 540 with 5.32ratio. Good job, keep it going... Last edited by The Wolf : 28th April 2012 at 11:07.
	() Thanks

17th August 2012, 11:00	#33
coloneljasi BHPian Join Date: Feb 2005 Location: KL-11 Posts: 686 Thanked: 253 Times View My Garage	Re: My new Bolero Di 4x4 and its Mods @ vak: Sorry to bump an old thread, but I think I saw your Bolero going towards Thrissur yesterday evening. I drove past in the opposite direction on my way back on the SH 69 to Calicut, near Lulu International. Have you done any further changes to your ride? Your Bolero looks like it means business!
	() Thanks

17th August 2012, 11:53	#34
drbones BHPian Join Date: Aug 2012 Location: Bhimavaram Posts: 242 Thanked: 2,031 Times View My Garage	Re: My new Bolero Di 4x4 and its Mods vak, good write up of your long term bolero 4x4. But bolero with out power steering is tough task daily, Brave decision this shows your passon for a 4x4. I think gypsy is good with out power steering, but no diesel in gypsy. I have enquired about bolero 4x4, but the dealer refuses to accept that bolero comes with 4x4. God save mahindra from the dealers. dealers are the culprits who are killing 4x4 s in india.
	() Thanks

18th August 2012, 20:24	#36
offroad_maniac BHPian Join Date: Aug 2008 Location: Thane-Mumbai Posts: 492 Thanked: 156 Times	One more thing for the gurus. Can we fit a gear lock on a 4wd Boleros? As the base of main gear lever and 4wd selector is quite close to each other. Dont trust dealers unless its done before. Also how safe is it to use the standard hub locks and continue to drive in 2wd mode?
	() Thanks

22nd August 2012, 13:01	#40
svsantosh Senior - BHPian Join Date: Mar 2008 Location: Dubai Posts: 4,289 Thanked: 8,081 Times View My Garage	Re: My new Bolero Di 4x4 and its Mods how about fitting it from co-driver's side? Some juggad is needed, but see the space/viability... some pics of product may help.
	() Thanks

22nd August 2012, 13:11	#41
starter Senior - BHPian Join Date: Jan 2009 Location: My city Posts: 1,140 Thanked: 930 Times	Re: My new Bolero Di 4x4 and its Mods But how does it help Santosh/Offroad_Maniac? Inspite of the gear lock, one can still use the 4wd selector and bring the car to neutral isn't it?
	() Thanks

24th October 2012, 09:42	#43
joethomasv BHPian Join Date: Jul 2007 Location: KL-44 , KA-12 Posts: 375 Thanked: 325 Times View My Garage	Re: My new Bolero Di 4x4 and its Mods Hi Vak, I'm trying to fix an ac in my Thar Di. Can you tell me which pulley you used for the install?
	() Thanks

24th October 2012, 10:28	#45
joethomasv BHPian Join Date: Jul 2007 Location: KL-44 , KA-12 Posts: 375 Thanked: 325 Times View My Garage	Re: My new Bolero Di 4x4 and its Mods Thanks for the quick reply. I have your Thar DI thread in my boomarks. The blower is already installed so there is no going back. I might have to move the passenger seat a few inches back though. The AC guy has sent the pulley to Kovai but I prefer an OEM one. I'll try to source the 2 slot pulley from Cochin.
	() Thanks