Mahindra Classic - Jeeping exercise

SPIKE ARRESTOR · 14th March 2010, 14:30

@Trammway, very well documented and nice info there, would be keeping a close watch on this thread.

Spike

svsantosh · 14th March 2010, 18:46

Wow... At last the 'posting' begins.

I see the gear wheels between the CJ3B and classic are very different. So what did you end up changing to solve these issues?

PS - is it best to remove the gearbox down to fix a OD, or do it whilst hosting the jeep up?

And the video, is is the entire OD unit? It is so small!!

PS - Bharani is becoming a celebrity... he needs to pay royalty back to you

trammway · 14th March 2010, 22:15

Quote:

Originally Posted by SPIKE ARRESTOR

@Trammway, very well documented and nice info there, would be keeping a close watch on this thread.

Spike

Spike I wish to hear from you, do you know any information about the PTO port / Transfercase main drive gear having some dimensional changes between the Mahindra Classic ones and CJ340/MM540 ones (with same KMT90 and T18 combination, only difference is that of 2 lever and single lever)?

Quote:

Originally Posted by svsantosh

Wow... At last the 'posting' begins.

I see the gear wheels between the CJ3B and classic are very different. So what did you end up changing to solve these issues?

PS - is it best to remove the gearbox down to fix a OD, or do it whilst hosting the jeep up?

And the video, is is the entire OD unit? It is so small!!

PS - Bharani is becoming a celebrity... he needs to pay royalty back to you

The drive gear has definite difference that I have already explained.

Nope, you don't need to remove the gearbox down to fit the OD.

Nope what you see is only the planetary gear unit of the OD, please check the previous posts where I have published the complete OD kit.

I think so, may be I will ask him for a discounted labor charges

I will wait till tomorrow afternoon for guessing of the road block at this point, otherwise I will post it tomorrow evening.

Tejas@perioimpl · 15th March 2010, 13:42

Quote:

Originally Posted by svsantosh

If the lac isnt a problem, then the 2 year waiting will tire you out.

Where did you get those figures? Herm replies to my emails within 24hours. He has promised to ship within 4 days of receiving any order.

And cost of the OD quoted to me is approx 42K INR + shipping.

Looking closely at this thread before deciding.

svsantosh · 15th March 2010, 14:14

Quote:

Originally Posted by Tejas@perioimpl

Where did you get those figures? Herm replies to my emails within 24hours. He has promised to ship within 4 days of receiving any order.

And cost of the OD quoted to me is approx 42K INR + shipping.

Looking closely at this thread before deciding.

Eh, Ok I exaggerated the lac. May be it was close to 70K. But regd the production waiting period, I got to check with my friend. Will revert asap. Thanks for the 42K figure BTW... Looks more afffordable now.

trammway · 15th March 2010, 14:36

Quote:

Originally Posted by Tejas@perioimpl

Where did you get those figures? Herm replies to my emails within 24hours. He has promised to ship within 4 days of receiving any order.

And cost of the OD quoted to me is approx 42K INR + shipping.

Looking closely at this thread before deciding.

Here is the quote I have received from Herm:

1 no. 29 tooth 15 spline overdrive (Mahindra)------------------$ 940.00
1 no. 4 speed shift linkage------------------------------------$ 60.00
1 no. single lever floor plate and rubber----------------------$ 15.00

sub total-------------$1015.00

shipping options:
USPS postal Service International Priority Mail--$ 170.00
BAX/Schenker-------------------------------------$ 120.00 (If I opt this for calculations)

Wire Transfer charges: 10+40+20 = $ 70

Note: Initially your bank will charge a fee associated with the wire transfer, domestic wires average about $10.00US,
international wires about $40.00 US
If your bank uses a mediator bank, there may be an additional charge, average $20.00 US

that could be deducted from the wire amount. This will delay your shipment, because the full amount has not been received by us.

So the total damage is USD: 1205 = INR 55430 (@46 per USD)

Santhosh said the waiting period from my experiences & learning and actual delays from Herm due to unavailability of parts.

Now Herm side delay's could be avoided as he is having few ODs in stock.

Tejas@perioimpl · 15th March 2010, 14:52

Quote:

Originally Posted by trammway

So the total damage is USD: 1205 = INR 55430 (@46 per USD)

Super break up!

How much time did it take for the shipment to arrive via USPS?

He told me the total weight is 25pounds. Is it correct?

Waiting for the remaining of your post on how you solved the roadblock.

trammway · 15th March 2010, 15:44

Quote:

Originally Posted by Tejas@perioimpl

Super break up!

How much time did it take for the shipment to arrive via USPS?

He told me the total weight is 25pounds. Is it correct?

Waiting for the remaining of your post on how you solved the roadblock.

Nope, I have not ordered and took the pack via international shipping option. Instead one of our TBHPian (guess who) with great gesture carried it all the way from US to India. However the shipping charges were incurred locally in US itself as he had less time and ordered from Herm through some overnight delivery option. Total came to the same figures.

Total weight of the consignment is around 10-15kg. I will post the next phase of installation with how the road block crossed information in this evening as I'm now sitting in my office. Need to upload lots of pics and videos ,please wait till EOD today.

svsantosh · 15th March 2010, 15:58

Quote:

Originally Posted by trammway

......as I'm now sitting in my office. Need to upload lots of pics and videos ,please wait till EOD today.

What do you think we do in Office.

If this post is I.T-filtered, I am dead...

Come on, keep a few excel files open, open 2 diaries next to you, have 4-5 printed papers next to you, put your chat into DND mode and start the pics, Anna!!

trammway · 15th March 2010, 18:15

Well, the road block as I mentioned in my previous post is explained in here.

The OD kit was supplied with a ring kind of stuff called Spacer, this will be the first component to sit before the planetary gear assembly.

Mahindra Classic - Jeeping exercise-img_6075.jpg

The spacer provides sufficient gap between the internal oil seal and planetary gear. Also the spacer sits above the main drive shaft.

Mahindra Classic - Jeeping exercise-img_6260.jpg

The spacer provided in Herm's overdrive kit is not fitting properly into the transfercase for two reason.

1. The height of the spacer is bit shorter than the Mahindra Classic's main drive gear spec (see the pic below)

Mahindra Classic - Jeeping exercise-explanation.jpg

2. Outer dia of the spacer is sort of smaller, hence it is not fixing properly with in the oil seal on the drive shaft / main gear wall. (outer side of the green circle shows the oil seal in transfercase, the new spacer's outer dia is bit smaller than the oil seal's inner dia)

Mahindra Classic - Jeeping exercise-img_6255.jpg

Now with out it if I install the OD, it will simply compress the oil seal and will create unnecessary friction with the transfer case inner wall.

Look at the following figure which shows the old main drive gear next to mahindra classic, the dia of the front portion is not matching to each other. The same goes with MM540/CJ340 main drive gear, hence the herm's spacer that came with OD kit is of the older MM540/CJ340 model transfer case.

Mahindra Classic - Jeeping exercise-copy-img_6267.jpg

To over come this issue, I need to fabricate a spacer that matches to the Mahindra Classic's oil seal inner dia and to match the drive shaft length.

How did custom made fabricated spacer looked like, how much was the damage to pocket ?

to be continued...

JeepCaptain · 15th March 2010, 18:33

Hi Siva,
Glad to see that you have started the OD installation. Waiting for more pics and videos and a finally a full fledged test drive report.

Just realised that your OD has already travelled about 20K Kilometers from Herms factory before it reached you and been through three continents!! North America, Europe and Asia.

Tejas@perioimpl · 15th March 2010, 19:15

Hope you have measured accurate dimensions of the new spacer!

Jaggu · 15th March 2010, 22:29

Siva please continue and kill this suspense please! all eyes glued into this thread!

svsantosh · 15th March 2010, 22:48

Quote:

Originally Posted by trammway

How did custom made fabricated spacer looked like, how much was the damage to pocket?

Did you fabricate a new one in lathe or CNC? Must have cost anything between 500-2000, depending on the complexity and raw material.

Quote:

Originally Posted by Tejas@perioimpl

Hope you have measured accurate dimensions of the new spacer!

Hehe, I can see the raised eyebrow. You dont want to put down half a lac and fabricate something you have no prior experience with!!

Quote:

Originally Posted by Jaggu

Siva please continue and kill this suspense please! all eyes glued into this thread!

+1, anna - this is too much suspense. Let the bird out...!!

PS - Hope Herm reads this thread, You can give a feedback to him explaining the fabrication you had to do...

trammway · 16th March 2010, 00:21

Quote:

Originally Posted by JeepCaptain

Hi Siva,
Glad to see that you have started the OD installation. Waiting for more pics and videos and a finally a full fledged test drive report.

Just realised that your OD has already travelled about 20K Kilometers from Herms factory before it reached you and been through three continents!! North America, Europe and Asia.

Without you I'm sure this is not happen mate. Thanks a ton.

Quote:

Originally Posted by Tejas@perioimpl

Hope you have measured accurate dimensions of the new spacer!

Ofcourse yes. Please watch out my next post for details

Quote:

Originally Posted by Jaggu

Siva please continue and kill this suspense please! all eyes glued into this thread!

he he he... ok this time I will take your request

Quote:

Originally Posted by svsantosh

Did you fabricate a new one in lathe or CNC? Must have cost anything between 500-2000, depending on the complexity and raw material.

+1, anna - this is too much suspense. Let the bird out...!!

PS - Hope Herm reads this thread, You can give a feedback to him explaining the fabrication you had to do...

The next episode follows, I will sure let Herm know about this thread after completion of the installation part.

I need to start posting the performance report after that

14th March 2010, 14:30	#196
SPIKE ARRESTOR Senior - BHPian Join Date: Nov 2009 Location: Germany Posts: 2,855 Thanked: 1,545 Times	@Trammway, very well documented and nice info there, would be keeping a close watch on this thread. Spike
	() Thanks

14th March 2010, 18:46	#197
svsantosh Senior - BHPian Join Date: Mar 2008 Location: Dubai Posts: 4,289 Thanked: 8,080 Times View My Garage	Wow... At last the 'posting' begins. I see the gear wheels between the CJ3B and classic are very different. So what did you end up changing to solve these issues? PS - is it best to remove the gearbox down to fix a OD, or do it whilst hosting the jeep up? And the video, is is the entire OD unit? It is so small!! PS - Bharani is becoming a celebrity... he needs to pay royalty back to you
	() Thanks

15th March 2010, 18:15	#205
trammway Senior - BHPian Join Date: Apr 2006 Location: Bridgewater USA Posts: 1,150 Thanked: 483 Times View My Garage	Well, the road block as I mentioned in my previous post is explained in here. The OD kit was supplied with a ring kind of stuff called Spacer, this will be the first component to sit before the planetary gear assembly. The spacer provides sufficient gap between the internal oil seal and planetary gear. Also the spacer sits above the main drive shaft. The spacer provided in Herm's overdrive kit is not fitting properly into the transfercase for two reason. 1. The height of the spacer is bit shorter than the Mahindra Classic's main drive gear spec (see the pic below) 2. Outer dia of the spacer is sort of smaller, hence it is not fixing properly with in the oil seal on the drive shaft / main gear wall. (outer side of the green circle shows the oil seal in transfercase, the new spacer's outer dia is bit smaller than the oil seal's inner dia) Now with out it if I install the OD, it will simply compress the oil seal and will create unnecessary friction with the transfer case inner wall. Look at the following figure which shows the old main drive gear next to mahindra classic, the dia of the front portion is not matching to each other. The same goes with MM540/CJ340 main drive gear, hence the herm's spacer that came with OD kit is of the older MM540/CJ340 model transfer case. To over come this issue, I need to fabricate a spacer that matches to the Mahindra Classic's oil seal inner dia and to match the drive shaft length. How did custom made fabricated spacer looked like, how much was the damage to pocket ? to be continued... Last edited by trammway : 15th March 2010 at 18:16.
	() Thanks

15th March 2010, 18:33	#206
JeepCaptain BHPian Join Date: Aug 2009 Location: Dubai / Gods Own Country -Kerala Posts: 864 Thanked: 493 Times View My Garage	All the Best Hi Siva, Glad to see that you have started the OD installation. Waiting for more pics and videos and a finally a full fledged test drive report. Just realised that your OD has already travelled about 20K Kilometers from Herms factory before it reached you and been through three continents!! North America, Europe and Asia.
	() Thanks

15th March 2010, 19:15	#207
Tejas@perioimpl Distinguished - BHPian Join Date: Sep 2008 Location: Bombay Posts: 4,428 Thanked: 9,764 Times View My Garage	Hope you have measured accurate dimensions of the new spacer!
	() Thanks

15th March 2010, 22:29	#208
Jaggu Team-BHP Support Join Date: May 2004 Location: Bangalore Posts: 20,369 Thanked: 17,301 Times	Siva please continue and kill this suspense please! all eyes glued into this thread!
	() Thanks