Soon, activities started rolling by procuring tools in the workshop, some basic, and one or two very exclusive. At the same time my mentors started the search to find out a clean desired engine-gearbox combination in all possible places. It was not very easy to get a matching 5-speed, 4x4 set-up with minimal modification to be done. And the availability of fund was not very generous. After around a week long hard toiling for hours, they finally got hold of the stuffs of satisfactory level.
The Isuzu was a low mileage engine, and the gearbox, was in even better condition, having a single lever shift 4x4 system.
The existing set up was taken out to keep in our disposal after proper oiling and all. The mounting of the Isuzu engine was bit different than the original ones. So new mounts were fabricated. The engine-gearbox got mounted and the jeep was finally sent to the workshop from Delhi for its makeover. I could have some understanding how important it is to make a correct alignment for the engine and gearbox. The best part of the set-up was that, it was a bolt-on addition without the requirement of any adapter plate in between, something we really appreciated. Some snaps to continue further:
The work begins
The rear view
The new engine mounts
The Isuzu in initial condition
Another accompanying modification was to get a new front shaft because of slight change in length requirement. This was properly fabricated under ‘strict’ supervision.
A tentative plan was chalked out as to how to go forward with the project. It was decided to 1st get the mechanical components serviced/overhauled to get the jeep into running condition with basic electric connections.
New electronic fuel pump was fitted as a companion to the Isuzu. An important addition was the brake booster, which improves the braking phenomenally. We decided to go for a brand new one. New clutch plate and accelerator pedals were also installed. The differentials, axles, hubs were done up. All the suspensions were renewed with new shackles. Some more snaps:
The new booster and clutch-accelerator assembly
The gearbox (note the 4x4 lever is missing)
Some other overhauling pics
The gentleman in the picture (not very clearly visible though!) is the man in charge. He is a great person, with an amazing eye on every detailing, doing everything on own in a very neat fashion, only needing an assistant to supply the tools and required stuffs. I was in no hurry to rush up the things, since it was a one-time build. Slowly and steadily the jeep started getting back its mechanical strength.
To be continued.......