Making of Legend.. My MM540 Mods

Jassy1313 · 1st September 2010, 22:21

you said that you have Bolero OKBJ Front and Bolero Rear axles on your jeep..
how much did you pay for the set?
have you changed the Hub and faced the Brake Drum to seat on the OKBJ Carrier Plate, to retain the 139.7 PCD?
the axles have LSD or you installed later?
please reply..

starter · 1st September 2010, 22:29

Please Tini

Please do not sell it.
You've built such a purposeful Jeep. Not only have you retained the Jeep character but also ensured that it could double up as a family friendly vehicle.
My suggestion would be to retain it and start using it regularly.
Finally, it is your call/decision.
Cheers,
Deepak

SPIKE ARRESTOR · 1st September 2010, 22:32

Tini, a few queries:-
1. Have you reinforced the long member near the RCBT mountings?
2. Have you chopped off the Targa band (B pillar area)? Does water drain away easily?
3. You had asked me details of the T-18 Transfer case and your first post mentions a BW mechanical transfer case, am I mistaken or something has transpired?

Spike

PS- Please relocate the coolant recovery bottle, it can be mounted on the sides of the deflector.

jeepster · 1st September 2010, 23:34

is it for sale?

Quote:

Originally Posted by Jassy1313

have you changed the Hub and faced the Brake Drum to seat on the OKBJ Carrier Plate, to retain the 139.7 PCD?

those are scorpio rims so pcd will be 160.2002 MM540

EDIT: check out following.

Bolero DI Turbo Engine
5 Speed NGT520 4x4 Gearbox
Hard Top
AC
Power Steering
Stereo with 9 Inch Speaker/Box
Bolero Open Knuckle Front Diffs/Axles
Bolero Wide Track Rear Axles
Front Free Wheeling Hubs
Yoko Geolander AT Tyres
Fully Floating Rear Axles
Hubs Converted to 160 PCD Bolero Hubs
Power Disc Brakes
Custom Radiator with increased lines
4.27 Axle Ratio
Snorkel

Team-BHP Classifieds - 2002 MM540 4x4 with Bolero 4x4 Aggregates - Powered by PhotoPost Classifieds

headers · 2nd September 2010, 07:32

Quote:

Originally Posted by jeepster

is it for sale?

those are scorpio rims so pcd will be 160.2002 MM540

EDIT: check out following.

Bolero DI Turbo Engine
5 Speed NGT520 4x4 Gearbox
Hard Top
AC
Power Steering
Stereo with 9 Inch Speaker/Box
Bolero Open Knuckle Front Diffs/Axles
Bolero Wide Track Rear Axles
Front Free Wheeling Hubs
Yoko Geolander AT Tyres
Fully Floating Rear Axles
Hubs Converted to 160 PCD Bolero Hubs
Power Disc Brakes
Custom Radiator with increased lines
4.27 Axle Ratio
Snorkel

Team-BHP Classifieds - 2002 MM540 4x4 with Bolero 4x4 Aggregates - Powered by PhotoPost Classifieds

It also ha[s]d Bilstein Shocks!!

4x4addict · 2nd September 2010, 12:25

Quote:

Originally Posted by Jassy1313

you said that you have Bolero OKBJ Front and Bolero Rear axles on your jeep..
how much did you pay for the set?
have you changed the Hub and faced the Brake Drum to seat on the OKBJ Carrier Plate, to retain the 139.7 PCD?
the axles have LSD or you installed later?
please reply..

35K and exchange for MM540 axles for the Bolero Set. I have converted to 160 PCD, so my hubs are from 4x4 Bolero along with DISC Brakes.

Quote:

Originally Posted by starter

Please Tini

Please do not sell it.
You've built such a purposeful Jeep. Not only have you retained the Jeep character but also ensured that it could double up as a family friendly vehicle.
My suggestion would be to retain it and start using it regularly.
Finally, it is your call/decision.
Cheers,
Deepak

I now have 4x4 Scorpio so I feel rather than have two HT/AC vehicles, I would rather retain my Scorpio and build a CJ340 from a new Major. I feel this is the best way to have a really updated CJ340 rather than buy an old one for ridiculous prices being asked and then upgrading it. There are plenty of used 4x4 majors in Kerala with the NGCS & OKBJ so they will be a good project vehicle for my CJ340 build.

Quote:

Originally Posted by SPIKE ARRESTOR

Tini, a few queries:-
1. Have you reinforced the long member near the RCBT mountings?
2. Have you chopped off the Targa band (B pillar area)? Does water drain away easily?
3. You had asked me details of the T-18 Transfer case and your first post mentions a BW mechanical transfer case, am I mistaken or something has transpired?
PS- Please relocate the coolant recovery bottle, it can be mounted on the sides of the deflector.

@spike:
1)Yes the long member has been reinforced for the RCBT mountings.
2) The B Pillar and windshield frame has been lowered by a few cms. Water drainage is not a problem, but I feel I could have sloped it some more front and back with a slight raise in the B-Pillar.
3) It is not BW, but T-18. There was some confusion earlier on but now I am clear that it is a T-18.
4) I plan to relocate the coolant recovery bottle.

Quote:

Originally Posted by jeepster

i
those are scorpio rims so pcd will be 160

Correct. Scorpio and Bolero are both 160 PCD so Bolero Hubs with Scorpio Rims is what I have.

SPIKE ARRESTOR · 2nd September 2010, 12:30

Quote:

Originally Posted by 4x4addict

I would rather retain my Scorpio and build a CJ340 from a new Major. I feel this is the best way to have a really updated CJ340 rather than buy an old one for ridiculous prices being asked and then upgrading it. There are plenty of used 4x4 majors in Kerala with the NGCS & OKBJ so they will be a good project vehicle for my CJ340 build.

Tini, in case you have any plans to get a brand new Major, ACT FAST!

Spike

JeepCaptain · 2nd September 2010, 14:18

Quote:

Originally Posted by SPIKE ARRESTOR

Tini, in case you have any plans to get a brand new Major, ACT FAST!

Spike

Spikey, Congrats on becoming Senior bhpian. i just noticed it today. Regarding your comment about acting fast, How many more months do we have to act??

JC

SPIKE ARRESTOR · 2nd September 2010, 15:08

Quote:

Originally Posted by JeepCaptain

Spikey, Congrats on becoming Senior bhpian. i just noticed it today. Regarding your comment about acting fast, How many more months do we have to act??

JC

Thanks Shibucha

. One more month, the notification says October 1.

JeepCaptain · 2nd September 2010, 18:06

Quote:

Originally Posted by SPIKE ARRESTOR

Thanks Shibucha

. One more month, the notification says October 1.

Just one month!! Oh Thats bad.!

So you guys pull the plug on Oct 1st right? And it will be available for may be few more months.

joshguy · 2nd September 2010, 21:40

Quote:

Originally Posted by SPIKE ARRESTOR

Tini, in case you have any plans to get a brand new Major, ACT FAST!

Spike

Spike whats the reason for it getting phased out? and when are you going to launch the THAR

jeepster · 3rd September 2010, 13:06

a confirmed source say that all DI or M2DI engines are being phased out.(in bolero platform)
& major has M2DI mill.

SPIKE ARRESTOR · 3rd September 2010, 13:23

M2DI is nothing but the same engine with Chain drive. The source possibly isn't correct, I feel so.

Spike

4x4addict · 6th November 2010, 18:24

Hi All,

Just wanted to update a few things that I upgrades/changes that I did recently.

The color of the hard top was changed from Silver to Matt black based on Kurien's suggestion and I feel it looks better than the Silver top.

I finally gave up trying to find the Lever assembly for the inline shifter that comes standard with the NGT520 and T18 combo in the Invader/Major. So I changed the T18 cover to change the shifter to the single lever MM550 assembly. This shifter assembly is much better as the lever directly engages the transfer case shafts where as the OEM set up on the NGT goes through a series of linkages which will result in some amount of play/weakness down the line. Finally, I can say that the 4x4 works perfectly...

I added an imported tow/pindle hook in the rear.

Front Winchplate and Bullbar to protect the winch has been added. Need to add the winch now. Just a bit wary since my jeep gets parked outside overnight and am a wary about the winch getting stolen.

With the added weight of the Winchplate, Top, DI Turbo Engine, Bull Bar & Winch, the front leafs were flattening out fairly quickly so I added a leaf to the front and now it seems just right. There is no extra jumpiness. Looks like the stock set up was too less for the the mods.

Added two JCB/Hella Work lights on both front corners. I find this very useful off-road and also when going through hairpin bends in ghat roads. You can actually see around the hairpin bend and won't run over a bison by mistake.

Talking about weight, I drove the jeep onto a weigh bridge and it tipped the scales at 1720 Kg. I feel this is not bad given the amount of stuff I have added to the jeep.

Also attaching some pictures of the interiors.

To sum it up, these are the list of upgrades done so far:

MDI3200 TC DI Turbo Engine
NGT520 Transmission with T18 Transfer Case
T18 Transfer Case shifer modified to use MM550 Type Single Lever
57" OKBJ Bolero 4x4 Axles
53" Fully Floating Bolero Rear Axles (Tubes Swapped and spacers added for the difference in track)
Hard Top
Air Conditioning
Worm & Roller Power Steering from Bolero 4x4.
JVC Stereo with 9" Speakers
Front Bucket Seats
Forward facing back seats
Bilstien Gas Shocks
Power Disc Brakes
Free Wheeling Hubs
Hubs converted to 160 PCD
235/70/16 Yoko Geolander AT Tires
Custom Radiator (Increased Lines)
Heavy Duty Rear Pindle Hook.
Snorkel
Euro Spec Jeep Wranger Tail Lights
Auburn Gear LSD
Custom Fender Extensions
Front & Rear Bull Bar
Side Bars with Extra Body mounts
Larger Fixed Windshield
KC Wide Angle Reverse Lights
The only pending thing remaining is to install the Smitty Bilt XRC8 Winch and them I will be done :-). Well maybe a XYLO D2 engine as well...

GrayBerry · 7th November 2010, 02:09

Quote:

Originally Posted by 4x4addict

Hi All,

Just wanted to update ----- remaining is to install the Smitty Bilt XRC8 Winch and them I will be done :-). Well maybe a XYLO D2 engine as well...

4x4addict:
You have a nice looking and purposeful Jeep my friend. I like the light on your front bumper, as you said you can look into the turns even before you turn. Was wondering if you need to connect them to your indicators,. forget it

its good as is. By the way, I still envy the stock looks of your jeep in its early days

.

1st September 2010, 22:21	#76
Jassy1313 BHPian Join Date: Feb 2007 Location: Mumbai Posts: 280 Thanked: 62 Times View My Garage	you said that you have Bolero OKBJ Front and Bolero Rear axles on your jeep.. how much did you pay for the set? have you changed the Hub and faced the Brake Drum to seat on the OKBJ Carrier Plate, to retain the 139.7 PCD? the axles have LSD or you installed later? please reply..
	() Thanks

1st September 2010, 22:29	#77
starter Senior - BHPian Join Date: Jan 2009 Location: BLR Posts: 1,059 Thanked: 727 Times	Please Tini Please do not sell it. You've built such a purposeful Jeep. Not only have you retained the Jeep character but also ensured that it could double up as a family friendly vehicle. My suggestion would be to retain it and start using it regularly. Finally, it is your call/decision. Cheers, Deepak
	() Thanks

1st September 2010, 22:32	#78
SPIKE ARRESTOR Senior - BHPian Join Date: Nov 2009 Location: Germany Posts: 2,778 Thanked: 1,135 Times	Tini, a few queries:- 1. Have you reinforced the long member near the RCBT mountings? 2. Have you chopped off the Targa band (B pillar area)? Does water drain away easily? 3. You had asked me details of the T-18 Transfer case and your first post mentions a BW mechanical transfer case, am I mistaken or something has transpired? Spike PS- Please relocate the coolant recovery bottle, it can be mounted on the sides of the deflector.
	() Thanks

3rd September 2010, 13:06	#87
jeepster Senior - BHPian Join Date: Oct 2008 Location: MH24 aka LATUR Posts: 1,626 Thanked: 1,435 Times View My Garage	a confirmed source say that all DI or M2DI engines are being phased out.(in bolero platform) & major has M2DI mill.
	() Thanks

3rd September 2010, 13:23	#88
SPIKE ARRESTOR Senior - BHPian Join Date: Nov 2009 Location: Germany Posts: 2,778 Thanked: 1,135 Times	M2DI is nothing but the same engine with Chain drive. The source possibly isn't correct, I feel so. Spike
	() Thanks

6th November 2010, 18:24	#89
4x4addict Distinguished - BHPian Join Date: Nov 2007 Location: Chennai Posts: 4,295 Thanked: 3,553 Times View My Garage	Few more upgrades Hi All, Just wanted to update a few things that I upgrades/changes that I did recently. The color of the hard top was changed from Silver to Matt black based on Kurien's suggestion and I feel it looks better than the Silver top. I finally gave up trying to find the Lever assembly for the inline shifter that comes standard with the NGT520 and T18 combo in the Invader/Major. So I changed the T18 cover to change the shifter to the single lever MM550 assembly. This shifter assembly is much better as the lever directly engages the transfer case shafts where as the OEM set up on the NGT goes through a series of linkages which will result in some amount of play/weakness down the line. Finally, I can say that the 4x4 works perfectly... I added an imported tow/pindle hook in the rear. Front Winchplate and Bullbar to protect the winch has been added. Need to add the winch now. Just a bit wary since my jeep gets parked outside overnight and am a wary about the winch getting stolen. With the added weight of the Winchplate, Top, DI Turbo Engine, Bull Bar & Winch, the front leafs were flattening out fairly quickly so I added a leaf to the front and now it seems just right. There is no extra jumpiness. Looks like the stock set up was too less for the the mods. Added two JCB/Hella Work lights on both front corners. I find this very useful off-road and also when going through hairpin bends in ghat roads. You can actually see around the hairpin bend and won't run over a bison by mistake. Talking about weight, I drove the jeep onto a weigh bridge and it tipped the scales at 1720 Kg. I feel this is not bad given the amount of stuff I have added to the jeep. Also attaching some pictures of the interiors. To sum it up, these are the list of upgrades done so far: MDI3200 TC DI Turbo Engine NGT520 Transmission with T18 Transfer Case T18 Transfer Case shifer modified to use MM550 Type Single Lever 57" OKBJ Bolero 4x4 Axles 53" Fully Floating Bolero Rear Axles (Tubes Swapped and spacers added for the difference in track) Hard Top Air Conditioning Worm & Roller Power Steering from Bolero 4x4. JVC Stereo with 9" Speakers Front Bucket Seats Forward facing back seats Bilstien Gas Shocks Power Disc Brakes Free Wheeling Hubs Hubs converted to 160 PCD 235/70/16 Yoko Geolander AT Tires Custom Radiator (Increased Lines) Heavy Duty Rear Pindle Hook. Snorkel Euro Spec Jeep Wranger Tail Lights Auburn Gear LSD Custom Fender Extensions Front & Rear Bull Bar Side Bars with Extra Body mounts Larger Fixed Windshield KC Wide Angle Reverse Lights The only pending thing remaining is to install the Smitty Bilt XRC8 Winch and them I will be done :-). Well maybe a XYLO D2 engine as well... Attached Images Last edited by 4x4addict : 6th November 2010 at 18:41.
	(1) Thanks

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