MUTT SUV Project

[aisheikh]

If you guys had been following my previous thread on G-Class Project Bling, I had mentioned that I will be back in action in September. So here I am :-)


Thanks to Saqib (Janj) and his team, I have now started the MUTT SUV Project. I will be posting major progess of the project on this thread. Feedback and comments will be highly appreciated.


To give a heads up, following mechanical modifications are expected:


Engine: Toyota 3C-TE (Turbo Diesel EFI 2.2 Liters)


Breaks: Currently original but later 4 Wheel Disk


Suspension: Front Stiffning and Lift


Gearbox: Currently original but later on 3C 5 Speed Manual


4x4: Currently original but later on Suzuki Sumari Hi-Lo


Differential: Currently original but later Limited Slip


Others: Power Steering, Power Breaks, Solenoid Cynlinder, Winch, Rollbar.

[aisheikh]

@julyseventysix
Some modification would be needed for hood adjustment. Eventually, I will be replacing the hood.

[aisheikh]

Today tested the Jeep at the Nov 1 4x4 Engaged Ravi Event. Sand Obstacles, River Bed, Dry Bed, and On Road. Superb performance.
Improvement in the stopping power and steering needed, so as to balance them with the engine's performance.

On Road and Off Road Test a complete Success!!

Thanks to Janj.

Now on to next round of performance mods.

[aisheikh]

One more thing. The gearbox ratio and matching with the engine was very good. However, smooth shifting was a problem. The gear had to be shifted with some delay and aligned with a sweet spot.

Guys please give suggestions on the gearbox improvements.

[aisheikh]

1st Offroad Test

[aisheikh]

Starting from today, I am putting the vehicle on reliability test. Yesterday during offroading the engine was slightly heating up due to small radiator. Today I tested the vehicle at high speeds. The clutch and gearbox are weak. I have parked the jeep in my garage. Will check for chamber leaks in the morning.

[DeeDee]

loved the power pack package of your Mutt... hope everything comes out as you have planned.... best of luck and keep us posted...

[aisheikh]

Originally Posted by DeeDee

loved the power pack package of your Mutt... hope everything comes out as you have planned.... best of luck and keep us posted...

Thanks DeeDee. You took the punga and I had to follow.B-)

[aisheikh]

Jeep Testing in progress:
Gearbox definitely has to be replaced as it is not matched for the engine. Gearbox and clutch oil leaking
Rear Differentials making sound. May have to mod diffs or replace them.
For on-road use I definitely need power steering and disk brakes.
Have installed seat covers for all 4 seats, as temporary means. But eventually will be replacing them.
Engine is very good.

[bugzy]

Originally Posted by aisheikh

Jeep Testing in progress: Gearbox definitely has to be replaced as it is not matched for the engine. Gearbox and clutch oil leaking Rear Differentials making sound. May have to mod diffs or replace them. For on-road use I definitely need power steering and disk brakes. Have installed seat covers for all 4 seats, as temporary means. But eventually will be replacing them. Engine is very good.

Great !!! that is the exactly the way to soup your 4x4 .... keep it on road so you can judge exactly is happening and what it needs ... hows the carbon fibre bonut coming along ???





Regards

[aisheikh]

Thanks bugzy for the support.
I had a strong feeling about the gearbox that it would need to be replace, but didn't expect that it would be so soon. The issue with replacing the gearbox is that the entire drivetrain would need modifications which includes 4x4, axle shafts, drive shafts, differentials, and engine adapter.
A strong contender for gearbox is Diahatsu Rocky 5 speed with hi lo 4X4. The differntials remain a question as currenty the rear diff is noisy, and matching it with a new gearbox is an unchartered territory
The suspension needs some oberhaul also, such as seals and rubber. The vehicle is very stiff from the rear, so would need to take 1 spring out of 2 on each side. Need to add longer front springs to balance out the ride and support additional weight of the diesel engine and winch.

Once I am upgrading the drivertrain I will also install power disk brakes, power steering, and bigger radiator.
The only fixing up I have done is that I got the front and rear seats poshished with Beage Leatherite.
Body modifications will happen after completion of the major mechanical modifications. I must say the jeep is a head turner without the hood, and it brings smiles to people's faces :-)

[aisheikh]

MUTT 1st Offroad Test

[Basharatu]

@
aisheikh




Good going, though I am not a big fan of mods but reliability is something we need in 4x4 to use it for hardcore off-roading. Best of Luck for the Project, it is looking hot without hood .

[aisheikh]

@Bashartu
I am looking to build a decent performance and reliable offroader, hence modifications are inevitable. Thanks for the support.

[Basharatu]

Originally Posted by aisheikh

@Bashartu I am looking to build a decent performance and reliable offroader, hence modifications are inevitable. Thanks for the support.

As I said earlier, agreed with Mods to get high & reliable performance , it should be rally fit upon completion of the project , your going with the good speed & as we did in our Pungaz, keep on doing R&D to get the best results on the 1st attempt.

[aisheikh]

Can't wait to have my jeep ready as per my specs. Looking forward to taking on the obstacles in Islamabad :-).

[Basharatu]

Originally Posted by aisheikh

Can't wait to have my jeep ready as per my specs. Looking forward to taking on the obstacles in Islamabad :-).

![endif]--spanArial Unicode MS","sans-serif";"Would love to see her performing in isloo. If you have planned for diff upgrade, would you also be going for diff locks @ front & rear?

[aisheikh]

@bashartu
I have still not found suitable diffs with locks for my modifications. I hear Gen 2 Pajero's front IFS is a potential contender.

[aisheikh]

For all those following this post, I need help in determining the best configuration of 4x4, 5 Speed Gearbox, and Differentials for the 3C Turbo Engine.

• What is the most effective 5 speed gearbox for on and off-road use?
• What 4x4 gearbox options are available?
• What differential options are available?
• Pros and Cons of having cross-linked vs geared axle shafts?

[sherwan_88]

Originally Posted by aisheikh

For all those following this post, I need help in determining the best configuration of 4x4, 5 Speed Gearbox, and Differentials for the 3C Turbo Engine.

• What is the most effective 5 speed gearbox for on and off-road use?
• What 4x4 gearbox options are available?
• What differential options are available?
• Pros and Cons of having cross-linked vs geared axle shafts?

aisheikh,

I own a Mutt which has almost 95% stock parts, and would like to answer your questions.

1. For a 3CT i'd recommend you get something out of a Pajero. My opinion only.

2. There is a lot of variety available, but the question would be which one would fit,weigh and perform best with a 3CT, i think you have Janj to answer that for you, as he's done all of it back in the stone age to his mutt.

3. I think Mercedes 220 diffs are almost bolt on and require a lot less modifications, while on the other hand you can mount a lot of different diffs, ranging from Toyota, Mitsubishi's and even Suzuki's.

4. U joints eat up almost 30-40%, when it actually reaches the wheels, and in mutts it is actually higher than that, too only just drive the rear wheels, there are 6 u joints from which the power is transmitted. This setup also requires a lot of tightening and adjustments on a daily basis. With my own personal experience i can tell you if you pop the clutch fast you'd have one or two broken u joints. If they don't break, they'll certainly end up loose or damage the diff. The u joints also need to greased a lot and quite often, and when fording, water enters very quickly.

As for "geared axle shafts" i don't know what you mean...

[NoWorNeVeR]

Any body with Merc go other diffs done ???

Plz show the work if you have taken pics