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-   -   My MM540XD upgrade (https://www.team-bhp.com/forum/4x4-vehicles/49375-my-mm540xd-upgrade-9.html)

Dear Arka,
Thanks a lot for sharing these pictures.
A couple of questions:
1) This metal plate on Header's Gypsy, is this what is called the skid plate?
2) Would a stock Gypsy articulate this much? If not, since this isn't SPOA, what other changes have been done to achieve this articulation?
Thanks once again Arka.
Cheers,
Deepak

PS: I simply love those wider axles on your Jeep. It looks awesome!

Arka,
From pictures it is clear that wider axles will have more articulation for the same set of springs!
Despite fouling the fender and limiting articulation your 540 could reach the same line that of Sanjays MM540, infact i feel your's did better. Now imagine it without fouling with fender. You almost had almost 1 inch left both rear and front!!

Headers Gypsy had a huge improvement...but still not in jeep category.:uncontrol Try your Bolero storm 2wd, i feel it will surpass your gypsy specially in reverse.

Headers i feel you should revert to older set up and just remove the front roll bar. Extra long shakle are prone to damage and may even bend leaf reverse under impact.

Well Thanks, this is an experiment and will firm up soon the same!

Hi Guys,

The Auto-Lockers were making a lot of noise and throwing the rear of the vehicle while locking up.

Sean Hameed suggested I tighten the adjusting shims to 0.5-1.5mm.

So just before the Chennai 15th Nov OTR, I got the differential re-installed,

The main culprit was a worn out differential pinion Cross Shaft, this was causing the Auto-Locker Coupler to move a few mm causing the noise and throw.

After the re-installation the noise has been reduced by 95%, now the locker clicks at extreme turns or slaloms.

Regards,

Arka

Hi Guys,

I wanted to definitely participate in the Bangalore Annual Event.

And had a list of work to be done on my MM540XD.

1) Wider Body bed i.e Armada/Bolero
This has made the body more stable, and taken a lot of stress from the body. On road the vehicle feels sure and off-road its has considerably reduced body roll.

2) Change the tyres to 7.00X16.
with an effective differential ratio of 5.13, the drive to Bnagalore and back was excruciatingly slow, so now it will always be 31/32" tyres i.e 7.50X16 NDMS.

The vehicle performed as usual on the trail, but on Day#2 morning I ripped my rear propeller shaft, as the diff rotated up, because the Spring Saddle weld got cut.

Luckily I did not damage the differential internals or the axles :D.

Regards,

Arka

I thought it was the DRIVERS mistake to be so slow Arka :uncontrol

Hi Guys,

Its time to start the Recce’s for TPC2010. So I decided to get the MM540XD in shape.

The Engine main bearing seal was shot and the engine was loosing oil, so it had to be serviced, since the engine was taken out, I decided to service the gearbox.

The following work was done

1) Engine
i) Changed Vale Stem Seal.
ii) FIP Hub gear/pinion. Was the cause of erratic firing and and delayed starts, after this change the strating is crisp, engine feels revitailsed.
iii) Chain Tensioner. (Timing Case)
iv) Main Bearing Oil Seal (Crankshaft).
v) Oil-Cooler Assy.

2) Gearbox/T-Case
i) Changed All the bearings.
ii) Changed Cover Assy and Clutch Plate.
iii) Breathers for G-Box & T-Case (7mm Banjo & Bolt) raised to inner (engine bay) firewall.
iv) Changed the Cross member as the older one has cracked.

3) Axles & Hub
i) Serviced and repacked the Wheel Bearings (3 of 8 were damaged due to water, Nov 2009) I am really impressed by the construction of the FFRA and its efficiency. The Hubs were greased and packed in Jan 2009 just before MGE48, and even after submerging in water, and one bearing being completely shattered, the rear right hub, did not show any signs of giving up.
ii) Serviced the Free Wheeling Hubs.

4) Seats
i) upholstered the front 2 seats
ii) upholstered the Rear (MM550) Seats

5) Leaf Spring :
i) Front 9
ii) Rear 10

6) Paint touch up.
i) Silencer bent Pipe
ii) Body (Sides & Tail Gate)
iii) Bumperettes

Regards,

Arka

PS - To Do
i) Tyres 7.50X16 Sand Grip/Bullet
ii) GPS
iii) Winch

Wha....??? No pics :eek:?

Pics of the vehicle after the work.

The Front Seat Covers were made in 2006 along with the Canvas top (Rip-Stop) and the same have been used.

Arka

why dont you treat your jeep with a 1/2 coats of painting ?:)

Hi Joshguy,

Why only 1-2 Coats, after (If & When) I, get the vehicle sand-blasted, only then will I do a comprehensive paint job.

Also that will have a 1 month down time.

Regards,

Arka

PS - For the cost I can easily convert to RCBT PS.

:uncontrol Thats Arka for you, who believes beauty is only skin deep! He probabaly would invest on paint job only when he thinks he has nothing else to do mechanicall on his jeep.....but that would never come!!:D

Hi Nookala.Vinod,

That day will come when my MM540XD has
1) XD3P-2A FIP
2) RCBT PS
3) Front Locker
4) New Tyres
5) MM550XD Tail Gate
6) MM550XD windscreen assy. (Natural HVAC)

Regards,

Arka

Arka,

i am sure currently we all getting the natural H=heating,V=Ventilation(may be more ventilation) in jeeps and gypsies.So u need only AC part from the HVAC option right?lol:

Raj

Hi Raj,

The Natural HVAC is an OEM option only on M&M JEEPs.

Only the ones which have the Tilting Wind Screen Glass Frame:D.

Keeping it open what a difference it makes :uncontrol.

Regards,

Arka