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A bit surprising, may be with a particular batch of NGT520s. Yes, there were problems with synchronizers which were corrected with new rings and hubs. This was somewhere around 2006-2007 though.

The SA may have told this to you, possible, as I do not know what is going on there since last year.:)

These are currently the most used transmissions with M&M vehicles (although that does not necessarily imply they must be trouble free).

EDIT- Is that also the reason why you insisted on having the KMT in your new Jeep?

Spike

Pratheesh which synchronizer is good? The bigger one or the smaller one?

Sreejesh

Thank you pratheesh just now I came from the spareparts shop:)

@ Samurai,

I do not own a thar, but got myself an humble cj3b which is doing its duty of ferrying me to unusual places.

On reading your quote 'Apparently, it has issues with synchronizer rings, they are getting too many complaints.' I am forced to seriously give it a thought, if Mahindra ever recall for replacement of faulty parts or something in the past unlike other players in the market? If at all they ought to or will , i wonder how it will be like for Mahindra's?:Shockked:

Hi Geje, will let you know the details in person. A bit heavy on the wallet thou. I'm really happy with the 2003 Di and KMT gearbox but is nowhere near the word refined. Think this is one of the noisiest engine/gearbox combos that we have among our team :D But love the instant torque and does manage to cruise around 80-90. So cant complain much but accept the fact that you cant have the best of both ends.

Hi sir, radiator serviced and problem sorted. Heard that it settles where the leak is happening and blocks the water from seeping out. Geje think you should hold your existing axles if your not planning a wider track.

Sir did manage to twist my cross member during the OTR and my gearbox had moved up. I could see the gap between the gear lever shield and platform. No problem with gears but humming started to raise every day. So changed crossmember and now back to normal.

One thing that Im very tempted to rework is a rollcage like this. Source team bhp.

Why do you need an OKBJ ? I would suggest, you go ahead and buy Barani's front and rear axles.
Get a transfer case from Mettupalayam/Muvattupuzha, change main shaft on your KMT 90
gear box and you have a 4 x 4.
But if you are keen on Okbj and NGT 520, I'll give you the contact no of the dealer, you'll have to make your own arrangements.
I had sourced these parts on behalf of certain jeepers, TEAM Bhpian's included, but they fail to understand that these are used parts. I had to cope up with some embarrassing comments from unsatisfied jeepers.
Regards

This should answer your question. They may be still making the faulty part along with the corrected part.

Yes, wanted something that is reliable and known to all mechanics.

My NGT520 gave me trouble from day one. Downshifting from 5 to 4, it easily slips into reverse. I want to tell you, that makes a wickedly bad noise! Up shifts from 4 to 5 a little dicey, too. All drivers have trouble shifting with this car. Shifts into reverse have become hard to do without grinding gears. I am at 74,000 now and I need a tranny rebuild on my NGT520. I am easy on tranny and clutch usually. Mahindra dealer in Pathenkot quoted me 8000 rupees to rebuild clutch and tranny both together.

I am converting it into a 4 wheel drive. Hence the change from stock Axles. Will need to change both the Front and Rear axle / Axle Housings.

My use is 50 % on road ( Highway) and 50 % off road. So a 5 speed gear box is a must.

Geje, from what you have posted, I feel you'll be spending close to 1 lakh. Do you think its worth the money. There's no guarantee that you will have a trouble free vehicle. Retain the kmt 90 gear box for the go time being.
Regards
Jerrycan

Its going to be the KMT 90 with a T 18 Transfer Case

My Configuration

53" Front Open Knuckle Axle Housing from a MAJOR; Cost 11000.00
Fully Floating Rear axle of an NGCS Army 550 with 19 spline axles, without LSD; Cost 18000.00
Both the above will have 160 PCD hubs to accommodate 16 inch rims.
The t 18 Transfer Case is going to be T 18 Single liver u type shifting: Cost 8000

Cost of Conversion 20000.00 ( Includes Over hauling of all the parts being changed)

Friends, your inputs and views are valuable, please advice.

Regards
Geje

is there any 53" OKBJ available ? Major OKBJ is 51"
Why you need a 53" FFRA ? then your front is 51"& rear is 53" ? what is the extra load / tough job you are doing with the rear FFRA? Same time you can get a 51" army rear axle with LSD and bigger/stronger axle, I don't think it break in your 50% or 80% Offroad :D .

Major PCD is 139.7 not 160.

Sir, You are right, It is 51' OKBJ on the front and SFRA from a 550 and the pitch is 139.7. It is not about the off road, I'am worried about. During week days I plant to use this Vehicle as a load carrier for a foundry. It'll carry loads up to 1 Ton. But that will surely not break the axles, I am sure. So SFRA it is.

Sir, Your jeep looks Macho with the new set of axles. Please do share the costs if you can. Please also share some pictures on the forum.
Thanks
Geje

Geje ,

Please No more "Sir".

Your 540 is with DP engine Right ? Its good to think about an Engine swap too:D

Good to hear that you are understanding the needed parts for the Job.

51" OKBJ on front
51" SFRA from army 550 on rear, You get the advantage of LSD with 30 spline axle (That army 30 spline axle is big and strong)
KMT90+T18 single shifter/double liver both will do the job
Offroad -ve offset steel wheels for wider track & better look.
MT/AT (30-31" is the best) tyre which suits your Budget.

or / sell the 540 as it is.. Buy a NGCS . I personally know few from Coorg with 58" FC axles and 57"+53" axles on their 540s all are saying it good for Photography :uncontrol . On road it behaves like a Boat. So if you want bigger track like 57",53" MRCBT 5 speed gearbox, bigger Engine.. go for NGCS.

- Sreejesh

Sir
I dont need an OKBJ, All I need is a Disc brake on the front axle, and Barani's axle has got a Drum. The Conversion cost from Drum Brakes to Disc alone will cost close to 15 K, add another 25 K towards the Axles, the total cost is Around 40,000.00. So I opted for Stock Axles from Marshall/NGCS or even a non NGCS 550

Do the Non NGCS 550 and 540 share the same steering box assy. Please shatre the details.
Thanks
Geje

The steering boxes are different.
The steering box on the 540s are worm and worm wheel type. On a non NGCS 550s it's recirculating ball type. Ngcs have bigger steering boxes also recirculating ball type.
Regards
Jerrycan