Tub Installed

Bell housing seal

Holy Smoke!

The engine fired a few days back! The mechanicals have been overhauled and the chassis is ready to accept the body.

PS: Avoid painting the chassis 'chemial sludge' blue-gray.

Engine rebuild:

Oil pump

The pistons

Transfer Case and PTO

PTO port

Intermediate shaft and gears

Output shaft and gears

PTO shaft

Axles rebuilt

The final drive ratio has been lowered to 5.875, the lowest there is for the Dana 44.

Front and rear axle assembly

My MM550XD rebuild

I am rebuilding an ex-army 99 MM550XD 4x4 into my daily driver cum off-roader. This vehicle is the first project for my workshop specializing in off-road vehicles.

The vehicle will be overhauled and modified to improve its off-road capabilities.

It will receive:

• 33" tyres
• The final drive ratio will be changed from 4.88 to 5.875
• A shackle lift
• Softer rear suspension
• The anti-roll bar will be removed
• Differential guards
• Rock sliders
• A roll cage for the driver and co-driver
• The fuel tank will be lifted
• Snorkel air intake
• Water resistant electricals
• HID headlamps

The doors have been removed as I found them to be quite a nuisance on my 540. The B pillar will be chopped. Detachable fabric doors will serve as protection from the elements.

I will eventually install a PTO winch and replace the rear LSD with a differential lock.
The vehicle will be capable of fording 1500mm of water. 

With my old MM540's wheels and tyres

The body removed for painting