Converting a MM540 into my Dream..

DesertKing · 27th March 2008, 18:27

Hi, I have just bought an MM540 4x4, 1989 modle in NOT RUNNING conditions (body and chasis are NOT BAD). It is so far used in some central govt department. I bought it in 42K without the engine. I did not buy the engine alongwith as I am putting a XDB3 intercooled engine which has been taken from a MM550XD 2000 model military jeep

. I paid 17K for this and it is in ok condition. It may require a bit repairing but hopefully not too much.

I have also bought the front and real axcel of Armada (including the rear bigger break drums/front disk + differential + double bearing hub).

I wanted to know if the differential of Armada and MM540 have the same final ratio. Need help of some Jeep Guru

Just want to add that I am going to give a bit similar look of Mahindra Thar but with a little bit different face (perhaps with little lower bonet and different headlights / indicators and different door lines and fixed front mirrors). Infect I like the Wranger look. Also planning to fit a power steering.

Stay in touch

Naren / 93143 92938
Jodhpur (Rajasthan)

sabret00the · 27th March 2008, 19:55

Wow 1st of all congrats dude...good to see someone buying a MM540 and trying to build to JEEP standards...it's my most favourite Mahindra model ever..although I'am not a JEEP guru nor do I own one but I used go to school in a Mahindra willy's when I was young and I could never get rid of the JEEP design of the 70s - 80s. For starters, I would suggest you to paint the vehicle in Dark Brown (non-metallic) keep it a topless and equip it with Sandgrips...all the best.

27th March 2008, 21:41

congrats man! quite a few people including me dreaming of an MM540. didnt know the MM550 came with an intercooler! can you have an intercooler without a turbo? would that be of any benefit?

you're looking at a lot of work, do you have any particular mechanic in mind?

will you be keeping a pictorial record of the build?

dinar · 27th March 2008, 22:08

The engine you bought has an intercooler?????? I don't think M&M ever launch the XD engines with turbo... although they had planed to turbo them. Are you trying to turbocharger it?

simply_sunny001 · 28th March 2008, 09:32

congrats Desertking

thats a nice buy and why dont you post some pics also.

DesertKing · 28th March 2008, 15:02

I am working with THE BEST mechanic of my town and he is the key person of this project. I have seen he is also very excited to go for these modifications. His name is GudduSa and he is having quite good hands on the desel engins.

Infect I am not sure what is intercooler but he told me that this engine is offcourse an intercooler one. This engine is taken from a military MM550XD make 2000. I just gave him a call to confirm if it is really intercooler and he confirmed me YES, it is. Right now the MM540 is in different parts... the body is with the denter and the chasis is with the Chasis specialist who is making the rear suspension wider (as in the new jeeps), and the engine is also opened. I will post some pics as soon as MM540 is quite in shape.

Also can somebody please advice me where can I find the MRF Sandgrip and also if they are redial once and what is the tyre size (ex 215 75 R16).

Note from the Team-BHP Support Staff : Please use the "edit" button if posting within 15 minutes of the first post, instead of creating another back-to-back post

nitrous · 28th March 2008, 15:28

MRF Sandgrip are nylon (non-radial) tyres.
I've driven these tyres on the most hardcore off-roading surfaces. I can't comment on the grip.But,very very tough!

kailashnj · 28th March 2008, 15:45

Congratualations on your new car buddy and that too which is hand made. Man I do envy you. I always wanted a classic jeep but could not get hold of one. But never thought something like this also can be done.

Keep on the good work and keep on posting, may be even that will inspire me.

maxbhp · 28th March 2008, 15:56

Quote:

Originally Posted by DessertKing

Hi, I have just bought an MM540 4x4, 1989 modle in NOT RUNNING conditions (body and chasis are NOT BAD). It is so far used in some central govt department. I bought it in 42K without the engine. I did not buy the engine alongwith as I am putting a XDB3 intercooled engine which has been taken from a MM550XD 2000 model military jeep

. I paid 17K for this and it is in ok condition. It may require a bit repairing but hopefully not too much.

I have also bought the front and real axcel of Armada (including the rear bigger break drums/front disk + differential + double bearing hub).

I wanted to know if the differential of Armada and MM540 have the same final ratio. Need help of some Jeep Guru

Just want to add that I am going to give a bit similar look of Mahindra Thar but with a little bit different face (perhaps with little lower bonet and different headlights / indicators and different door lines and fixed front mirrors). Infect I like the Wranger look. Also planning to fit a power steering.

Stay in touch

Naren / 93143 92938
Jodhpur (Rajasthan)

Wow ! you seemed to have worked everything out. All the best for your project.
PS : Try a PS job with the rectangular head lights up front. It dramatically improves the look.

28th March 2008, 16:15

@maxbhp- real jeeps have round headlights

maddy42 · 28th March 2008, 16:26

Best of luck budy and congrats . welcome to the jeeps club

krazydriver84 · 28th March 2008, 16:31

Congrats on the jeep matey !

Hey desert king, how about a pictorial thread. that would really be interesting for all of us who just dream about having a jeep one day.

GTO · 28th March 2008, 17:35

Quote:

Infect I am not sure what is intercooler but he told me that this engine is offcourse an intercooler one. This engine is taken from a military MM550XD make 2000.

AFAIK the army Jeeps did NOT sell with an intercooler. They sold with an oil cooler

DesertKing · 28th March 2008, 18:30

GTO is right. It is infect an OIL COOLER. Sorry for the mistake.

dinar · 28th March 2008, 20:35

Hey could you post some pics of the oil cooler and how it's attached to the engine, I mean the plumbing for the oil to circulate through the system. I have always wondered why we are not given oil coolers on our cars.

27th March 2008, 18:27	#1
DesertKing BHPian Join Date: Mar 2008 Location: Jodhpur, Rajasthan Posts: 463 Thanked: 24 Times View My Garage	Converting a MM540 into my Dream.. Hi, I have just bought an MM540 4x4, 1989 modle in NOT RUNNING conditions (body and chasis are NOT BAD). It is so far used in some central govt department. I bought it in 42K without the engine. I did not buy the engine alongwith as I am putting a XDB3 intercooled engine which has been taken from a MM550XD 2000 model military jeep . I paid 17K for this and it is in ok condition. It may require a bit repairing but hopefully not too much. I have also bought the front and real axcel of Armada (including the rear bigger break drums/front disk + differential + double bearing hub). I wanted to know if the differential of Armada and MM540 have the same final ratio. Need help of some Jeep Guru Just want to add that I am going to give a bit similar look of Mahindra Thar but with a little bit different face (perhaps with little lower bonet and different headlights / indicators and different door lines and fixed front mirrors). Infect I like the Wranger look. Also planning to fit a power steering. Stay in touch Naren / 93143 92938 Jodhpur (Rajasthan)
	() Thanks

27th March 2008, 19:55	#2
sabret00the BHPian Join Date: Mar 2006 Location: YYC \| BLR \| CCU Posts: 692 Thanked: 55 Times View My Garage	Wow 1st of all congrats dude...good to see someone buying a MM540 and trying to build to JEEP standards...it's my most favourite Mahindra model ever..although I'am not a JEEP guru nor do I own one but I used go to school in a Mahindra willy's when I was young and I could never get rid of the JEEP design of the 70s - 80s. For starters, I would suggest you to paint the vehicle in Dark Brown (non-metallic) keep it a topless and equip it with Sandgrips...all the best. Last edited by sabret00the : 27th March 2008 at 19:59.
	() Thanks

27th March 2008, 21:41	#3
rippergeo Posts: n/a	congrats man! quite a few people including me dreaming of an MM540. didnt know the MM550 came with an intercooler! can you have an intercooler without a turbo? would that be of any benefit? you're looking at a lot of work, do you have any particular mechanic in mind? will you be keeping a pictorial record of the build?
	() Thanks

27th March 2008, 22:08	#4
dinar Senior - BHPian Join Date: Mar 2006 Location: goa Posts: 1,066 Thanked: 57 Times	The engine you bought has an intercooler?????? I don't think M&M ever launch the XD engines with turbo... although they had planed to turbo them. Are you trying to turbocharger it?
	() Thanks

28th March 2008, 09:32	#5
simply_sunny001 Senior - BHPian Join Date: Jun 2007 Location: London & Rohtak Posts: 1,340 Thanked: 18 Times View My Garage	congrats Desertking thats a nice buy and why dont you post some pics also.
	() Thanks

28th March 2008, 15:02	#6
DesertKing BHPian Join Date: Mar 2008 Location: Jodhpur, Rajasthan Posts: 463 Thanked: 24 Times View My Garage	I am working with THE BEST mechanic of my town and he is the key person of this project. I have seen he is also very excited to go for these modifications. His name is GudduSa and he is having quite good hands on the desel engins. Infect I am not sure what is intercooler but he told me that this engine is offcourse an intercooler one. This engine is taken from a military MM550XD make 2000. I just gave him a call to confirm if it is really intercooler and he confirmed me YES, it is. Right now the MM540 is in different parts... the body is with the denter and the chasis is with the Chasis specialist who is making the rear suspension wider (as in the new jeeps), and the engine is also opened. I will post some pics as soon as MM540 is quite in shape. Also can somebody please advice me where can I find the MRF Sandgrip and also if they are redial once and what is the tyre size (ex 215 75 R16). Note from the Team-BHP Support Staff : Please use the "edit" button if posting within 15 minutes of the first post, instead of creating another back-to-back post Last edited by Technocrat : 28th March 2008 at 18:41.
	() Thanks

28th March 2008, 15:28	#7
nitrous Senior - BHPian Join Date: May 2004 Location: UAE/Lon/Madras Posts: 6,965 Thanked: 325 Times View My Garage	MRF Sandgrip are nylon (non-radial) tyres. I've driven these tyres on the most hardcore off-roading surfaces. I can't comment on the grip.But,very very tough!
	() Thanks

28th March 2008, 15:45	#8
kailashnj BHPian Join Date: Oct 2006 Location: Mumbai Posts: 958 Thanked: 375 Times	Congratualations on your new car buddy and that too which is hand made. Man I do envy you. I always wanted a classic jeep but could not get hold of one. But never thought something like this also can be done. Keep on the good work and keep on posting, may be even that will inspire me.
	() Thanks

28th March 2008, 16:15	#10
rippergeo Posts: n/a	@maxbhp- real jeeps have round headlights
	() Thanks

28th March 2008, 16:26	#11
maddy42 Senior - BHPian Join Date: Aug 2007 Location: Coorg Posts: 2,131 Thanked: 1,328 Times View My Garage	Best of luck budy and congrats . welcome to the jeeps club
	() Thanks

28th March 2008, 16:31	#12
krazydriver84 BHPian Join Date: Oct 2007 Location: Kolkata + Gurgaon Posts: 428 Thanked: 44 Times View My Garage	Congrats on the jeep matey ! Hey desert king, how about a pictorial thread. that would really be interesting for all of us who just dream about having a jeep one day.
	() Thanks

28th March 2008, 18:30	#14
DesertKing BHPian Join Date: Mar 2008 Location: Jodhpur, Rajasthan Posts: 463 Thanked: 24 Times View My Garage	GTO is right. It is infect an OIL COOLER. Sorry for the mistake.
	() Thanks

28th March 2008, 20:35	#15
dinar Senior - BHPian Join Date: Mar 2006 Location: goa Posts: 1,066 Thanked: 57 Times	Hey could you post some pics of the oil cooler and how it's attached to the engine, I mean the plumbing for the oil to circulate through the system. I have always wondered why we are not given oil coolers on our cars.
	() Thanks