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-   -   My MM540XD upgrade (https://www.team-bhp.com/forum/4x4-vehicles/49375-my-mm540xd-upgrade-3.html)

Once the dates were finalized for Munnar OTR, I decided to upgrade my MM540XD a bit more.

The Following Work was done

1) Strip the old rusted body
2) Strip/Prime/Paint the Chassis
3) Install a new Tub (old 1987 MM540DP) and new Body beds.
4) Change the rear Axle to Bolero

Regards,

Arka

Only to complain later that Munnar trail was not challenging enough.:uncontrol

Arka, that tub looks familiar ??

Hi Arka, are you going to rust proof it after painting? What will you use to do this if so?

Why did you change to Bolero axles? Wider stance?

Hi Dirty_Dan,

I will sand blast the body and do the minor tinkering and then considering one of the following Primers

1) Polyurethane Primer
2) Expoxy Primer
3) Zinc Sulphate
4) Red Oxide

While tinkering I have given strict instruction not to use Bondo/metal Paste.

Because the metal paste absorbs water and rust the sheet metal.

Bolero Axles.

After the Front OKBJ conversion the track difference was 6".
1) Vehicle was looking very funny
2) I wanted to switch to One Piece FFRA. The older setup the outer flange develops play/slack and cuts the axle splines. ( suffered that twice)

Also wrt NGCS MM550XD (post 2004). They use 53" Front and Rear Track.

The Following work was done

1) The Old body was removed from the chassis
2) The chassis was scrapped of old paint
3) Chassis was washed with washing soda
4) Chassis was primed & painted
5) New Body (1987) was fitted with new body beds/mounts

Dear Arka,
I've been researching quite a lot on 4X4s available in market currently (affordable ones though). I think the new Major (CL550) comes with the differential ratio of 3.73:1. I am a real rookie in this, so maybe, i am wrong. If so, please excuse me.
Cheers,
Deepak

wonderful arka,

You are practically doing a mini restoration project. Work happening at lightening pace i suppose!! What tyres are you planning to replace your current NDMS?

Long time since we met...let us meet up some time!! :-)))))

P.S- Must appriciate your sourcing ability, you sourced rare bolero 4wd axles and now a complete body which seems to be in good condition!

Since my front track was 57" and Rear track was 51".

I decided to change the rear track to the Bolero Differential.

The Only catch was the Bolero Differential was off-set to the left where as the MM540 differential is off-set to the right.

So I had the Bolero Differential Axle Tubes switched around. stupid:

The First Batch of Pictures -
LSD
Differential Housing and switched tubes
Inner Oil Seal
Pinion Yoke replaced the Companion Flange.

so, now you have a right offset diff?? What is the length of bolero rear axle? 53inch?

I thought MM550 NGCS came with 53 front and 51 rear. 57 inch of your isnt too broad?

Hi Vinod,

I was under the impression that the NGCS was 53" Front and 53" FFRA.

Regards,

Arka

The New 1 Piece FFRA.

Pictures of
1) Drum 139.7 PCD
2) Hub 139.7 PCD
3) Comparison of the Spindles
4) FFRA Assembly

Now you will have clean rear rims without oil stains!!:-))))

i can see that you have army rims, what tyres are you putting on those?

FK

MRF Sand Grip 7.50X16 for Sand and Rocky terrain

MRF NDMS 7.00X16 for Muddy Terrain.

I'm looking out for good Mud-Terrain (Maxxis/BFG) in 235-85-16/245-75-16/255-85-16