Need help Regarding MM540/550

kd7202 · 18th October 2010, 09:45

@ 4x4addict - My jeep's a 2WD although I suspect that it used to be a 4WD some time in the past. It still has a opening on the floor next to the gear lever.

The reason I was thinking of a 5 speed gear box was because the engine rises when I cross 60 kmph on 4th gear although there is still enough and more power.

Anyway, if it's not possible, I'll just live with it as suggested by you.

Thanks

KD

kd7202 · 18th October 2010, 21:20

@ 4x4addict - Just wanted to tell you.

Your MM540 was the role model for mine when I was getting it tinkered & painted. Looks exactly like yours minus the extra lights & broad tyres but with a black soft top.

kd7202 · 24th October 2010, 13:41

Hi guys,

Can anyone help me in sourcing a used, fairly good XD3P engine and 5 speed gear box ? Its for my 2WD MM540.

My mech says some repairs are necessary for the existing XDP4.9 engine and 4 speed gear box which would cost me approx. 20K.

Alternatively , he suggested that I upgrade to the XD3P engine + 5 speed gear box. He says this may be available for around 40K to 45K in Bangalore but we'll have to search around as we may not get both together at the same time.

He also said that he would be able to mate a 5-speed gear box to the existing engine. One of the early Bolero gear boxes. I need to do a cost analysis on this.

Used XD3P engine + 5 speed gear box Vs. overhauling the existing XDP4.9 engine and add a 5 speed gear box !! How effective would be the second option ?

Is 45K a reasonable price to pay for the XD3P engine & 5 speed gear box ?

Need some guidance in this matter.

Thanks in advance.

Cheers

KD

jeepster · 24th October 2010, 22:47

Quote:

Originally Posted by kd7202

Used XD3P engine + 5 speed gear box Vs. overhauling the existing XDP4.9 engine and add a 5 speed gear box !! How effective would be the second option ?

my opinion is overhaul your xd3p & get a good BA10 gearbox.

or if you have some extra time & money you can go for Nissan, isuzu or other Engine+GB options too.

http://www.team-bhp.com/forum/4x4-ve...40-reborn.html

http://www.team-bhp.com/forum/4x4-ve...del-mm540.html

http://www.team-bhp.com/forum/modifications-accessories/84983-jeep-wrangler-jk-automatic-conversion.html

http://www.team-bhp.com/forum/modifications-accessories/8517-what-new-engine-jeep.html

http://www.team-bhp.com/forum/modifications-accessories/35098-installing-5-speed-tranny-mm540-mm550.html

rgds,
Nikhil

please copy & past above links. some of them are not working.

kd7202 · 25th October 2010, 09:50

Hi Jeepster,

Thanks for the inputs. My existing engine is a XDP4.90 and not a XD3P. I am actually looking for a XD3P engine and 5 speed gear box.

My mech says he'll be able to mate a 5 speed gearbox to my existing XDP4.90 engine, so if I can look at buying only the gearbox as well.

Cheers

KD

4x4addict · 25th October 2010, 11:49

Quote:

Originally Posted by kd7202

Hi Jeepster,
My mech says he'll be able to mate a 5 speed gearbox to my existing XDP4.90 engine, so if I can look at buying only the gearbox as well.

5-Speed can be mated using an adapter plate. You can pick up only the gearbox if you don't need the engine gearbox combo.

kd7202 · 25th October 2010, 14:51

@ 4x4addict - Thanks. I'll start the search for a 5-speed gearbox.

My existing gearbox has a problem, when I engage first gear and accelerate, the jeep makes a noise like a loaded lorry although the noise is not there in the other gears. Mech says this can be rectified by overhauling the gearbox.

But nothing like getting a 5-speed gearbox. Any idea where I can get one ? And cost ?

Thanks

KD

jeepster · 28th October 2010, 18:37

the best person to contact will be ex670c.

melsingh · 13th November 2010, 15:15

Quote:

Originally Posted by kd7202

@ 4x4addict - Thanks. I'll start the search for a 5-speed gearbox.

My existing gearbox has a problem, when I engage first gear and accelerate, the jeep makes a noise like a loaded lorry although the noise is not there in the other gears. Mech says this can be rectified by overhauling the gearbox.

But nothing like getting a 5-speed gearbox. Any idea where I can get one ? And cost ?

Thanks

KD

Hi, I think all MM540s have the same problem over a period in time, don't worry, it's a common complaint.

I've just put in a 5-speed Scorpio GB to my existing 2.1 Peugeot and it works just fine...I can get anywhere from 90-110 or even more (haven't pushed that hard till date), but there were some minor adjustments that had to be done and some trial runs to and fro from B'lore to Ooty to get it right. I still feel there is more that the engine can do with a slightly better ratio but I'm content mate...

I got mine for 29k with all repairs, the starter and flywheel (Armada Grand) along with the beds, etc. I don't know if this is a good deal, but it was sourced close to Coimbatore. Do let me know if you're interested, PM me and I'll call up a few guys that sourced it for me...Cheers!!!

kd7202 · 26th December 2010, 19:28

Hi

I am getting an Isuzu 5-speed gear box from the Bangalore gujri for about 6K. Its from a Contessa. The guy selling it to me says its in good shape and does'nt need any repairs, can be mated to the engine using an adaptor plate which he will source for me if possible.

Mine is a MM540 2WD with a Peugeot 2112 cc engine.

Apart from the adaptor plate, what else will I need to buy/modify in order to mate the gearbox to the engine ? The guy was talking about differential gear ratios to be changed, shortening the propeller shaft and some more technical gobbledegook which I did'nt understand.

Can someone please guide me in this ?

Thanks in advance

KD

4x4addict · 27th December 2010, 09:23

@KD:

Apart from the adapter plate you will need to shorten the rear prop shaft as the BA10 is a long gearbox compared to the KMT90 you have. I don't have the exact gear ratios of the Isuzu BA10 configuration in the contessa. Don't change the differential ratio until you have driven the vehicle with the new gearbox and tested the performance.

You are already on the 4.88 OEM mm540 diff ration. The next option is 5.38 which will be too short and you will loose the benefit of having made your jeep a 5 speed.

Stick with the current ration and use it for a while before you decide.

kd7202 · 27th December 2010, 10:36

@ 4x4addict : You mean retain the existing 4.88 diff ratio with the new gearbox ?

What do you mean when you say 5.38 would be too short ? Will low end power be reduced if I change it to 5.38 ?

All I am looking at is some top end speed. With the existing 4-speed gearbox I am not able to do more than 70 kmph.

Any idea how much these modifications would cost ? Adaptor plate, shortening the prop shaft, tinkering work, etc.,

Cheers

KD

Red Liner · 27th December 2010, 13:31

Quote:

Originally Posted by kd7202

What do you mean when you say 5.38 would be too short ? Will low end power be reduced if I change it to 5.38 ?

All I am looking at is some top end speed. With the existing 4-speed gearbox I am not able to do more than 70 kmph.

KD

Your top end speed will reduce. Your pick-up will increase. If you want more top end speed and not much low end grunt, then move to the ratios available across 3.xx

4x4addict · 27th December 2010, 21:03

I suggest stick with the 4.88 or go down to 4.27 at the most. Anything less than that and your 61 bhp peugot engine will not be able to move the jeep at a decent pace.

shekaran · 27th December 2010, 23:18

am waiting eagerly to know the results of mating the isuzu gb with xdp ???
KD sir, how was the results of the boric acid powder treatment ? did you use in the differential and test the drive ? whats the mileage gains ? pls post detailed results of the engine, gerabox, and also the differentials.
HAPPY NEW YEAR WISHES TO ALL TEAM BHPIANS !!!

18th October 2010, 09:45	#31
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	@ 4x4addict - My jeep's a 2WD although I suspect that it used to be a 4WD some time in the past. It still has a opening on the floor next to the gear lever. The reason I was thinking of a 5 speed gear box was because the engine rises when I cross 60 kmph on 4th gear although there is still enough and more power. Anyway, if it's not possible, I'll just live with it as suggested by you. Thanks KD
	() Thanks

18th October 2010, 21:20	#32
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	@ 4x4addict - Just wanted to tell you. Your MM540 was the role model for mine when I was getting it tinkered & painted. Looks exactly like yours minus the extra lights & broad tyres but with a black soft top.
	() Thanks

24th October 2010, 13:41	#33
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	Hi guys, Can anyone help me in sourcing a used, fairly good XD3P engine and 5 speed gear box ? Its for my 2WD MM540. My mech says some repairs are necessary for the existing XDP4.9 engine and 4 speed gear box which would cost me approx. 20K. Alternatively , he suggested that I upgrade to the XD3P engine + 5 speed gear box. He says this may be available for around 40K to 45K in Bangalore but we'll have to search around as we may not get both together at the same time. He also said that he would be able to mate a 5-speed gear box to the existing engine. One of the early Bolero gear boxes. I need to do a cost analysis on this. Used XD3P engine + 5 speed gear box Vs. overhauling the existing XDP4.9 engine and add a 5 speed gear box !! How effective would be the second option ? Is 45K a reasonable price to pay for the XD3P engine & 5 speed gear box ? Need some guidance in this matter. Thanks in advance. Cheers KD
	() Thanks

25th October 2010, 09:50	#35
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	Hi Jeepster, Thanks for the inputs. My existing engine is a XDP4.90 and not a XD3P. I am actually looking for a XD3P engine and 5 speed gear box. My mech says he'll be able to mate a 5 speed gearbox to my existing XDP4.90 engine, so if I can look at buying only the gearbox as well. Cheers KD
	() Thanks

25th October 2010, 14:51	#37
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	@ 4x4addict - Thanks. I'll start the search for a 5-speed gearbox. My existing gearbox has a problem, when I engage first gear and accelerate, the jeep makes a noise like a loaded lorry although the noise is not there in the other gears. Mech says this can be rectified by overhauling the gearbox. But nothing like getting a 5-speed gearbox. Any idea where I can get one ? And cost ? Thanks KD
	() Thanks

28th October 2010, 18:37	#38
jeepster Senior - BHPian Join Date: Oct 2008 Location: MH24 aka LATUR Posts: 1,694 Thanked: 1,927 Times View My Garage	the best person to contact will be ex670c.
	() Thanks

26th December 2010, 19:28	#40
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	Re: Need help Regarding MM540/550 Hi I am getting an Isuzu 5-speed gear box from the Bangalore gujri for about 6K. Its from a Contessa. The guy selling it to me says its in good shape and does'nt need any repairs, can be mated to the engine using an adaptor plate which he will source for me if possible. Mine is a MM540 2WD with a Peugeot 2112 cc engine. Apart from the adaptor plate, what else will I need to buy/modify in order to mate the gearbox to the engine ? The guy was talking about differential gear ratios to be changed, shortening the propeller shaft and some more technical gobbledegook which I did'nt understand. Can someone please guide me in this ? Thanks in advance KD
	() Thanks

27th December 2010, 09:23	#41
4x4addict Distinguished - BHPian Join Date: Nov 2007 Location: Chennai Posts: 4,483 Thanked: 4,532 Times View My Garage Infractions: 0/1 (5)	Re: Need help Regarding MM540/550 @KD: Apart from the adapter plate you will need to shorten the rear prop shaft as the BA10 is a long gearbox compared to the KMT90 you have. I don't have the exact gear ratios of the Isuzu BA10 configuration in the contessa. Don't change the differential ratio until you have driven the vehicle with the new gearbox and tested the performance. You are already on the 4.88 OEM mm540 diff ration. The next option is 5.38 which will be too short and you will loose the benefit of having made your jeep a 5 speed. Stick with the current ration and use it for a while before you decide.
	() Thanks

27th December 2010, 10:36	#42
kd7202 BHPian Join Date: Sep 2010 Location: Bangalore Posts: 52 Thanked: 6 Times	Re: Need help Regarding MM540/550 @ 4x4addict : You mean retain the existing 4.88 diff ratio with the new gearbox ? What do you mean when you say 5.38 would be too short ? Will low end power be reduced if I change it to 5.38 ? All I am looking at is some top end speed. With the existing 4-speed gearbox I am not able to do more than 70 kmph. Any idea how much these modifications would cost ? Adaptor plate, shortening the prop shaft, tinkering work, etc., Cheers KD
	() Thanks

27th December 2010, 21:03	#44
4x4addict Distinguished - BHPian Join Date: Nov 2007 Location: Chennai Posts: 4,483 Thanked: 4,532 Times View My Garage Infractions: 0/1 (5)	Re: Need help Regarding MM540/550 I suggest stick with the 4.88 or go down to 4.27 at the most. Anything less than that and your 61 bhp peugot engine will not be able to move the jeep at a decent pace.
	() Thanks

27th December 2010, 23:18	#45
shekaran BHPian Join Date: Aug 2007 Location: Puducherry Posts: 245 Thanked: 77 Times View My Garage	Re: Need help Regarding MM540/550 am waiting eagerly to know the results of mating the isuzu gb with xdp ??? KD sir, how was the results of the boric acid powder treatment ? did you use in the differential and test the drive ? whats the mileage gains ? pls post detailed results of the engine, gerabox, and also the differentials. HAPPY NEW YEAR WISHES TO ALL TEAM BHPIANS !!!
	() Thanks