[svsantosh]

GB is up, fitting a GB against gravity is probably inhuman if done without a hoist...!!

Anyways, my back is sore, along with 3 other guys, too late to fit all other add'ons, left it for tommorow morning.

[svsantosh]

Is this a Dana 41 axle? It has some USA Patent markings on it (see prev page) and it has 10 spline... It is a 4-feet track axle.

[Aroy]

If you are loosing power in the third (top) gear, then it is you clutch slipping. Used to happen in my Ambassador. If you can, check the spring pressure of the clutch, also change the clutch pads if you are not changing the plate. In case your spring pressure is low, change them, else
- Clutch will keep slipping
- There will be power loss
- High fuel consumption
- Clutch will wear out in no time

If you can, check the output from your Dynamo/Alternator
- Connect a Voltmeter across battery and an Ammeter in series with alternator lead. Used to have a 30-0-30 meter in my car.
- Switch all the lights on
- Rev the engine hard and note the voltage as well as current

If all is well your voltage would be in the range of 14V - 15V, and current drawn between 15A and 25A for 4 Headlights and 4 parking lights.

Similarly check battery charging by connecting the ammeter in series with power main coming out of the battery. If all is well, recollecting my Ambassador days, with all lights off the battery charging current should be between 5A and 30A.

[svsantosh]

Originally Posted by Aroy

If you are loosing power in the third (top) gear, then it is you clutch slipping.

If clutch is slipping there should be abnormal increase in REV/RPMs, right? Here, I am loosing RPMs, figuratively speaking - if I rev to 3000 in 2nd gear (nearly top), when I shift to 3rd it comes to nearly 500~, stalling speed!! But the low torque of diesel just keeps turning the crank at a very lazy RPM, after nearly 20-25 seconds it picks up RPMs slowly and steadily...!!

[Aroy]

Originally Posted by svsantosh

If clutch is slipping there should be abnormal increase in REV/RPMs, right? Here, I am loosing RPMs, figuratively speaking - if I rev to 3000 in 2nd gear (nearly top), when I shift to 3rd it comes to nearly 500~, stalling speed!! But the low torque of diesel just keeps turning the crank at a very lazy RPM, after nearly 20-25 seconds it picks up RPMs slowly and steadily...!!

What I have experienced (of course more than 20 years ago), is that when the clutch is slipping, it requires quite some RPM for it to bite. When you are changing gears, you normally leave the accelerator, engage the clutch and then change the gear. In this process if the clutch loose its "bite", the transmission is no longer moving the crank. One way to check this is to press the accelerator immediately after changing gear and then if the engine revs up but the jeep does not it is the clutch.

Otherwise, the only reason left is that you engine is not able to take up the torque at third gear initially, and that opens up a Pandora's box of issues (best ignored till other options are exhausted).

Just an idea, could it be that the third gear is not engaging properly (teeth missing/not meshing, or shaft jammed, or else as the 3rd is direct the other gears are not dis engaging) and presenting a high load, which meshes after some hunting. That can be checked easily by isolating the GB and rotating shafts by hand, if there is any problem in GB then while you can rotate the input shaft in neutral, 1st and 2nd, 3rd would be stiff or even impossible to turn.

[catchkumar]

Thanks Aroy,

We are suspecting the loss of power due to the vintage diesel pump CAV Rotodiesel.
Looking at the option to change it to a Mico Pump.
If this doesn't seem to be the problem can the Jeep Gurus on the forum shed some light please.

Regards,
Kumar

[Sutripta]

^^^^^
Hi,
In all probability, the governing system inside the pump is gummed up.

Both my 500DP and Armada Grand had CAV pumps. Both landed up with the problem of stalling on the overrun. If it is not too far gone, running a couple of tankfuls with Iftex-d should show improvement. If not, pump will have to be stripped.

Most pump repairers concentrate only on the plungers and distributor plate. In an old vehicle, very likely both of these (and injectors) will need work. But that addresses other problems like hard starting, smoke etc. It is not likely to solve your problem.

Regards
Sutripta

[svsantosh]

The Jeep is at the mechs place, wasnt ready completely so had to miss a big bangy gathering. But how else to test a rebuilt gearbox and clutch? Simple - put it thru its 1st ever OTR.

Kumar - For your eyes only

This is a new trail in Hosur found by a Jeeper Rakesh, more on the Hosur trails thread.

-------------------

[catchkumar]

WOOOW! Finally my first OTR
It was great fun with a mix of obstacles to break ice for a newbie like me :-)
We also had some recovery work with my jeep getting stuck & not wanting to start on a small hillock.
Overall an excellent training session filled with fun :-)
Am sure there is much more in store as we get the jeep build to a level.
I just can't thank enough the following people -
Santosh for all your time, efforts & your patience in getting the Jeep OTR ready & me to drive it.
Arul - for being along all the while during the build of the jeep & for the excellent spotting skills guiding a novice.
Rakesh - for finding this new spot in hosur for us to have fun.
Ganesh - It wouldn't have been possible to enjoy these moments without your photos.

Thanks a lot guys for going out of your way.. well can i say (going OTR) ;-) for everything.

Regards,
Kumar

[svsantosh]

Picked up a Mico FIP (diesel pump), nozzle set with pipes for 2.5K from bangy gujri. Hope it gives the much needed boost to the engine over the stupid TVS (aka) RotoDiesel pump...

[Aroy]

Originally Posted by catchkumar

Thanks Aroy,

We are suspecting the loss of power due to the vintage diesel pump CAV Rotodiesel.
Looking at the option to change it to a Mico Pump.
If this doesn't seem to be the problem can the Jeep Gurus on the forum shed some light please.

Regards,
Kumar

I would have thought it so, except that you are getting revs in other gears. A faulty pump would starve the engine at high RPM in every gear. I see that the diesel pump parts are going to be replaced and hope that solves your problems. If not you are back to square one.

[ganesh_bbr]

Originally Posted by catchkumar

WOOOW! Finally my first OTR
It was great fun with a mix of obstacles to break ice for a newbie like me :-)
We also had some recovery work with my jeep getting stuck & not wanting to start on a small hillock.
Overall an excellent training session filled with fun :-)
Am sure there is much more in store as we get the jeep build to a level.
I just can't thank enough the following people -
Santosh for all your time, efforts & your patience in getting the Jeep OTR ready & me to drive it.
Arul - for being along all the while during the build of the jeep & for the excellent spotting skills guiding a novice.
Rakesh - for finding this new spot in hosur for us to have fun.
Ganesh - It wouldn't have been possible to enjoy these moments without your photos.

Thanks a lot guys for going out of your way.. well can i say (going OTR) ;-) for everything.

Regards,
Kumar

Your welcome Kumar, good to know you have picked up a Mico pump and sad i cannot join a ride this weekend with you guys :(

[svsantosh]

Changing the FIP and checking the timing. Change will happen tomm morning 1st thing, meanwhile njoy the pics.

Please note the odd oil pump from the base of the engine, it is connected to the alternator rear. It is slightly leaking, need to get it fixed.

[svsantosh]

Mico FIP put in place, nozzles in place
Fender, grill, radiator in place
Starter motor removed/refit to arrest a irritating noise
Coil-Spring Clutch finger adjusted - gear changes ultra smooth now

Now the jeep needs only half a crank to fire to life - feels more rev happy now

Power thru gears lot better, but still not like a 4+1 KMT GB jeep with 5.38 axles. I am now thinking this jeep does not have 5.38, may be lot less, in the range of 4.2x for F.E..!!

Need to open up the diff covers to count the crown/pinion ratios.

Oh, last but not the least - for the 1st time in her life...

SHE CRAWLS..!!!

[svsantosh]

The Jeep is back in Bangalore - kumar's home...Yipee.

Kumar, please post your 1st impressions.

Last minute work - pump tuned for more idling (crawl speed) and more pickup. And 1 MAJOR IRRITATING noise was sorted out in the clutch control cable.

More on it later...