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Mahindra Thar CRDe, Repair Manual

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Mahindra Thar CRDe Repair Manual Download Page 128

Repair Manual                                                                                            MAN-00

190

 

 

THAR

 

CRDe

 

BS-IV

                                                                             

        

            MAY

 

2012

/Rev 1

 

The repair methods given by the manufacturer in this document are based on the technical specifications at the time of release. The methods may be modified as a result of changes introduced by the 

manufacturer in the production of the various component units and accessories from which the vehicles are manufactured. The reproduction, translation, transmission, in part  or whole of the present 

document, are prohibited without the prior written consent of Mahindra & Mahindra Ltd.  The use of this document by any person other than the trained personnel, at the Authorized Service Centre of 

Mahindra & Mahindra Ltd., will amount to unauthorized use and shall be liable for penalty/prosecution© 2012 Mahindra & Mahindra Ltd.

 

Clutch slippage 

 

Observation 

Causes 

Remedial action 

Disc facing worn out. 

1.

 

Normal wear. 

2.

 

Clutch riding. 

3.

 

Insufficient diaphragm 
spring clamp load. 

4.

 

Faulty release 
mechanism. 

5.

 

Vehicle being driven 
despite slipping clutch. 

6.

 

Bad driving practice of 
allowing the clutch to 
slip far too long. 

 

Replace clutch disc 

 

Replace clutch plate 

 

Replace clutch plate & cover 
assembly. 

 

Replace , and bleed/ 

 

 

Customer to be informed. 

 

 

Customer to be informed. 

 

Clutch disc facing 
contaminated with oil, 
grease or clutch fluid. 

Leak at : 
1.

 

Crankshaft rear end oil 
seal 

2.

 

Leak through the input 
shaft  

3.

 

Excess amount of grease 
applied to the input 
shaft splines 

 

 

Replace seal & disc. Clean cover 
assembly. 

 

Replace seal & disc. Clean cover 
assembly. 

 

Apply less grease. Replace clutch 
disc. Clean cover assembly. 

Clutch is running partially 
disengaged. 

 Release bearing carrier 
sticky. 

 

Replace bearing / carrier. 

 

Flywheel height incorrect. 

1.

 

Improperly machined 
flywheel.  

2.

 

Excess machining done. 

 

Replace flywheel. 

Wrong disc or pressure plate 
used. 

Use the correct parts 

 

Replace the parts after 
comparison. 

Clutch disc/ cover or 
diaphragm spring warped. 

1.

 

Improper tightening or 
loosening procedure. 

 
2.

 

Rough handling of clutch 
plate or cover assembly 

 

Replace the parts and tighten as 
per sequence. 

 

 

Replace the parts, ensure that 
the rough handling is avoided 

Flywheel side clutch facing 
surface – torn/ nicked/ worn 

Flywheel surface ,scored and 
having light notch  

 

Reduce the scoring and nicks by 
sand paper. Reduce if scoring 
deeper. 

Clutch disc facing burnt. 
Excessive glazing of the 
flywheel & pressure plate. 

1.

 

Frequent operation 
under high loads or hard 
acceleration conditions 

 
2.

 

Frequent clutch riding by 
the driver. 

 

Roughen the  flywheel face with 
sandpaper. Replace clutch plate 
& cover assembly. 

 

The driver has to be alerted to 
avoid repeat failure. 

Clutch facing broken 

Improper storage-  clutch 
plate dropped prior to 
fitting. 

 

Replace. 

Fouling marks on the torsion 
damper. 

Improper fitment- 
assembled the wrong way 
around 

 

Rectify 

 

 

 

 

Page 126

Summary of Contents for Thar CRDe

Page 1: ...1 of 2 MAN 00190 ALL INFORMATION CONTAINED IN THIS MANUAL IS MOST UP TO DATE AT THE TIME OF PUBLICATION HOWEVER SPECIFICATIONS AND PROCEDURES ARE SUBJECT TO CHANGE WITHOUT NOTICE THIS MANUAL IS STRICTLY MEANT FOR RESTRICTED INTERNAL CIRCULATION WITHIN M M AUTHORIZED DEALER SERVICE CENTERS RELEASED BY TECHNICAL PUBLICATION CELL MAHINDRA MAHINDRA LTD Rev1 MAY 2012 www teknetmahindra com ...

Page 2: ... 2012 Mahindra Mahindra Ltd All rights reserved This book may not be reproduced or copied in whole or in part without the written permission of Mahindra Mahindra Ltd ...

Page 3: ... It contain information on the operation and maintenance of the THAR CRDe AC BS III BS IV as well as descriptions of the major units and their functions in relation to the other components of the System To ensure customer satisfaction with Mahindra products proper service and maintenance by Mahindra Dealer Technicians is essential Technician should know and understand the content of this manual be...

Page 4: ...ument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Table of Content How to use this manual Safety Instructions Vehicle Specification Vehic...

Page 5: ...g the aggregate from the vehicle Dismantling overhauling section covers the detailed process and procedures to be followed while repairing the system This is generally carried out after removing the aggregate system from the vehicle Assembly section covers the detailed process and procedures to be followed while repairing the system Tightening torques is the specified torque values for all crucial...

Page 6: ...c or flammable materials make sure that the area you work in is well ventilated Make sure that the Transmission Transfer Case Oil Exhaust system has cooled down sufficiently before attempting to remove any components for your safety Use correct lifting devices Whenever raising a vehicle for service be sure to follow the instructions Keep work area clean dry and well organized Keep tools and parts ...

Page 7: ...e negative cable first and then the positive cable When reconnecting the battery connect the positive cable first and then the negative cable and replace the terminal cover Whenever you use oil seals gaskets packing O rings locking washers split pins self locking nuts and certain other parts as specified be sure to use new ones Also before installing new gaskets packing etc be sure to remove any r...

Page 8: ...R CRDe BS III BS IV vehicle general specifications data PARAMETER MM 540 THAR CRDe Vehicle Dimensions Wheel base mm 2430 Overall width mm 1710 Overall length mm 3920 Overall height mm 1930 Front track mm 1445 Rear track mm 1346 Min ground clearance mm 200 Vehicle Weights Maximum GVW kg for rigid vehicles 2200 Maximum GCW kg for articulated combination vehicles N A Maximum FAW kg 1100 Maximum RAW k...

Page 9: ...39 Reverse 3 52 1 15 13 Number of axles Steered Non Steered Steered Front Non Steered Rear Driven Both Non driven N A Front axle Type Full floating hypoid type Toe in Toe out mm 12 to 18 at wheel rim per wheel Total Toe in 1 to 3 mm Camber angle 0 1º50 Difference between LH and RH 20 Caster angle 2 75 1º Difference between LH and RH 1º King pin angle 10 6 1 0 Rear axle Type Single Tandem Tridem Mu...

Page 10: ...ems Ltd Model RHD Oil Specification Caltex ATF Texamatic 1278 Dexron III Shell Donax TG Dexron III Oil capacity l 1 Lit Pressure setting kg cm2 bar kPa 75 bar Min turning circle diameter mm 11500 Min turning circle clearance diameter mm 11800 Clearance Minimum road clearance 200 mm Approach angle 46 Unladen Departure angle 30 Unladen Ramp over angle 15 Unladen Suspension Type and description Leaf ...

Page 11: ...COL Type Incorporated in speedometer Fuel tank Material Nominal thickness mm EDD steel 0 75 THK EDD steel Capacity Liters 60 Brake Service brake Brief description Dual hydraulic circuit with tandem master cylinder with vacuum assisted servo Auto Slack Adjuster Fitted Yes No Optional Yes ABS Fitted Yes No Optional No Front Disc Drum 226 mm dia Disc Rear Disc Drum 282 HNSS dia Drum Total braking are...

Page 12: ...from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prose...

Page 13: ...document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Engine 2 6L NEF CRDe Table of Content Description Trouble Shooting Care of the Syste...

Page 14: ...urbocharger controls the boost to 2 2 bar The compressed air is cooled by the charge intercooler which is mounted upstream of the turbocharger The cooled air enters the inlet manifold s plenum and it enters the Cast iron cylinder head through the inlet valves having a 45 degree angle A boost pressure sensor is incorporated in the system to measure the air boost The piston features re entrant type ...

Page 15: ...connect it with the compression gauge Disconnect the engine RPM sensor or phase sensor connector so that the engine does not start Crank the engine Note the compression value should be 30 bars Repeat the procedure for the other cylinder Refer to the Specification for the value Engine cylinder Head Gasket Failure Diagnosis A leaking engine cylinder head gasket usually results in loss of power loss ...

Page 16: ...pect replace the broken parts Check Adjust tappet clearance Engine does not give full power 1 Air intake restricted 2 Clogged fuel filter 3 Incorrect tappet clearance 4 Defective injectors 5 Air leaks in pressure line after turbocharger Turbo to intercooler intercooler intercooler to intake manifold 6 Air leak in pipe manifold 7 Fuel return pipe to tank blocked 8 Boost pressure pipe hose assembly ...

Page 17: ...rcooler intercooler intercooler to inlet manifold Check the EGR valve Remove restriction or replace parts Replace manifold gasket or parts Overhaul engine Excessive oil consumption 1 Cracked vacuum line hoses 2 Clogged air filter element 3 Restriction in air intake to compressor duct 4 Restrictions in turbocharger oil drain line 5 Restriction in crankcase breather 6 Damaged oil separator 7 Turboch...

Page 18: ...nk the engine 1 Weak battery 2 Corroded or loose battery connection 3 Faulty starter 4 Improper earthing Check the battery specific gravity Clean tighten battery connections Repair starter Rectify earthing Noisy valves 1 Tappets loose 2 Rocker arms touching the rocker cover 3 Thin or diluted oil 4 Low oil pressure 5 Bent push rods 6 Worn rocker arms 7 Worn valve guides 8 Excessive runout of valve ...

Page 19: ...il has to have do an additional load of lubricating and cooling the Turbocharger shaft If any oil of lower specification is used it can break down under the high thermal load at the turbine end of the shaft especially during the hot shutdown This oil grade also ensures that the oil consumption is within the desire limits Use Maximile Supreme Grade of oils The Oil change intervals are first at 5000...

Page 20: ...of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs The in car repairs which can be carried out are Tappet...

Page 21: ...secution 2012 Mahindra Mahindra Ltd Tappet setting 1 Remove the oil filler cap 2 Remove the oil separator pipe from the ladder frame sump to the rocker cover 3 Remove the tappet cover mounting Allen screws along with the rubber washer 4 Remove the tappet cover 5 Remove NVH Cover then Rocker Arm Cover with Gasket 6 Adjust the tappet clearance as per the following procedure Bring no 1 piston at TDC ...

Page 22: ... will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Accessory Belt tension Adjustment 1 Check the Belt Tension Turn on the Belt Tension Gauge select reading mode in Hertz Hz hold the probe approximately 5mm distance in Front of the belt CAUTION Do not touch the probe to the belt this can damage the probe as shown in the illustration above by X Ta...

Page 23: ... Loosen the Tensioner Pulley Nut Take out the pulley assembly with Dust Shield washer take the belt out 3 Take the belt out 4 Put the new belt in place fit the Tensioner Pulley Assembly along with dust shield washer on the bracket hand tighten the nut Tighten the Tensioner Pulley Nut with torque of 32 5 2 5 Nm 5 Tighten the Tensioner Bolt so as to get the specified belt tension follow the accessor...

Page 24: ...ten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd High Pressure Pump Removal Refitment Remove tappet cover Bring the 1st cylinder in compression Note To confirm the first cylinder ...

Page 25: ... any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd If the piston is not at TDC then the holes will not align with the block As a consequence when the MST is used subsequently the MST can break Rotate the engine to align three holes of High Press...

Page 26: ...without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Oil filter removal refitting Remove the right side wheel apron Remove the oil filter using the MST 545 CAUTI...

Page 27: ...ohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Turbocharger removal Refitment Remove the right side wheel apron Remove the oil filter using the MS...

Page 28: ...prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the exhaust pipe from after the elbow Access is only after lifting it on a two post or in ...

Page 29: ...sent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Cylinder Head Gasket Removal Refitment 1 Remove the rocker cover 2 Remove the I...

Page 30: ...rse of the tightening sequence Remove the Cylinder head assembly Measure the length of the cylinder head bolt If it is up to 135 mm then the bolt can be reused If the length is more than 135 mm use new bolt The cylinder head gasket is of the Multi Layer Steel MLRS Type gasket Though it can be assembled either way it is recommended that for optimum performance the Top which is identified by the let...

Page 31: ...t document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Working principle of the various subsystems of the Engine The various subsystems a...

Page 32: ... from the oil separator to the Air inlet hose which is normal However if it is excessive please look for all the causes mentioned in the high blow bye Oil circulation system An external gear type pump sucks the oil through the strainer The oil pump is driven by the gear which is mounted on the crankshaft The oil pump delivers pressurized oil to the supply bore in the block This oil is delivered to...

Page 33: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd mounting bracket The oil then enters the rocker shaft Oil enters the rocker bushing at through two holes facing the bottom half At the same time it sprays from the oil hole at the side of the rocker to lubricate the valve stem and the surfaces over which the valve cap slides The oil ...

Page 34: ... the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Oil filter bracket pressure relief valve in oil filter bracket is deleted Crack opening pressure of relief valve in oil pump has been reduced from 6 bar to 4 5 bar Oil pressure sensor is mounted on main oil galleries...

Page 35: ...he use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Removal of the engine from the vehicle Disconnect the battery cables remove the battery Remove the bonnet Remove the radiator drain cock Collect the coolant if the cool...

Page 36: ...ra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the exhaust pipe at the Turbocharger outlet elbow Remove the oil filter using the MST 545 Remove the Turbocharger mounting bolts and remove the Turbochar...

Page 37: ...r whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the hose connected from the water pump to heater and a...

Page 38: ...nnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the vacuum hose from the vacuum pump in alternator to booster Drain the oil from the sump Attach lifting device Remove the front insulators mounting bolts Remove the gearbox mounting Allen screws Pull out and lift the engine fr...

Page 39: ... use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Loosen the tensioner bolt first Loosen the belt tension with the bolt on bracket Remove the accessory belt While assembly take care that main drive pulley is assembled co...

Page 40: ...factured The reproduction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd R...

Page 41: ...the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Bring the first cylinder into compression Confirm using the MST Remove t...

Page 42: ...es of FIP sprocket with three tapped hole provided on crank case for mounting threaded pins of FIP removal tool FIT the three nos threaded pins on crankcase through HPP sprocket holes and tightened with 17 mm spanner Insert three slotted pins in the other three holes of HPP sprocket and rest against crankcase face Now slide pins in the slot so that bottom portion of slot will butt against the back...

Page 43: ...nel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Do not remove all the pins i e detail no 2 5 till HPP is reassembled on the sprocket If the MST is removed while the FIP is not in place then chance of sprocket getting bent and later the chain failure is high Remove rocker cover Remov...

Page 44: ... present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the connecting rod caps and take out the pistons Rotate the engine b...

Page 45: ... prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Lock the flywheel using the MST 252 and loosen the flywheel mounting bolts Remove the flywheel Remove the rear end oil ...

Page 46: ...urnal If scoring is nominal and will not the increase the oil clearance then the crankshaft can be used in as it is condition However if it is unacceptable then the journal has to be ground up to service limits only Any deep groove in the rear end oil seal seating area is unacceptable It will result in oil leaks Valve If valve tip is worn out ridged then not acceptable Main bearing and connecting ...

Page 47: ...tightened up to yield point And the 2 stage ensures that the clamping load for each bolt is within a very close tolerance Cylinder head bolts 10 nos Maximum length 136 6 135 4 mm Main Bearing Bolts 10 nos Maximum length 90 6 89 4mm Connecting rod bolts 08 nos Replace every time Flywheel bolts 06nos Maximum length 29 58 30 42 mm Cylinder block Top face Ensure that the tapping for the cylinder head ...

Page 48: ...lls before assembling on to the block or connecting rod Ensure that the bearing shells are located properly in the notches Oil seals Ensure that All the oil seals are fitted using the dolly MST Always ensure that the lip is coated with grease before fitment Apply engine oil on the outside diameter of seal The receiving bore should be free of burrs dent Engine Testing After the engine is reassemble...

Page 49: ...ayout of Cylinders Firing Order 4 Cylinder Inline 1 3 4 2 Direction of rotation Clockwise from fan side Compression Ratio 17 8 1 Compression Pressure Standard Service Limit 30 bar 1 Variation difference Piston Re entrant Bowl Piston Pin Full floating Surface hardened ground Oil grade Quantity API grade CH4 Viscosity Index 15W40 6 litres Maximile brand Cylinder liner Replaceable wet type Cast Iron ...

Page 50: ...e Standard Service Limit 0 047 0 025 0 05 Gudgeon pin to piston pin hole clearance Standard Service Limit 0 017 0 004 0 03 Piston weights grading A B C D E 836 840 gm 841 845 gm 846 850 gm 851 855 gm 856 860 gm Connecting rod grading as per weights F G H I J K L M N O P R S T U Recommended for service replacement 1260 1265 1270 1275 1280 1285 1290 1295 1300 1305 1310 1315 1320 1325 to 1330 M i e 1...

Page 51: ... rod bent Standard Service Limit 0 25 0 40 Valve spring Free Length Squareness Installed Load Installed length Standard Service Limit 53 6 50 6 0 15 0 2 381 5N 43 mm 347 N Valve seat angle 44 45 to 45 Valve stem O D Inlet Exhaust 6 95 7 10 6 95 7 10 Valve to Valve guide clearance Inlet Exhaust 0 03 0 07 0 05 0 09 Thickness of the valve head Standard Service Limit 2 0 1 5 Chain Crank Sprocket Idler...

Page 52: ...ahindra Ltd Crankshaft journal OD Roundness Ovality Cylindricity Taper Standard Service Limit 59 0 58 981 0 005 0 03 0 008 0 02 Undersize of the c s journal pin OD 0 25mm US 0 50 mm US 0 75 mm US Dimensions of the journal 58 75 58 371 58 50 58 481 58 25 58 231 Crankshaft bend CAUTION Standard Service Limit 0 025 0 06 FILLETS ARE HARDENED DO NOT ATTEMPT TO STRAIGTEN Crankshaft fillet radius Standar...

Page 53: ...ll be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Lubricants Sealants Mahindra Maximile Supreme Or any other engine oil conforming to API grade CH4 or above and a viscosity Index of 15W 40 If any oil conforming to CG4 grade is used then the oil change interval is 7000 Kms Oils of MIL 2104 C or below are not acceptable RTV silicone sealant RHODOSEAL Part number 0024532 to be used Betw...

Page 54: ...linder head 90Nm 60 60 66 4 Lbft 60 60 Connecting rod cap Mounting bolts 45 Nm 90 33 Lbft 90 Main Bearing cap 168 17 Nm 123 12 5 Lbft Flywheel 90 Nm 60 66 Lbft 60 Cranks shaft pulley apply oil on bolt before tightening 90 Nm 90 90 Cam sprocket mounting bolts 135 10 Nm HPP Mounting Nut 30 3 Nm Idler Shaft Mounting Bolts M8 X 1 25 M7 X 1 00 25 3 Nm 15 3 Nm HPP sprocket lock nut 70 5 Nm Camshaft thru...

Page 55: ...or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Special Tools Description Part No Sketch Usage View Piston R...

Page 56: ... are manufactured The reproduction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahin...

Page 57: ...anslation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Air Intake System Table of Co...

Page 58: ...air enters the air cleaner housing at the bottom and leaves at the top The air cleaner is made up of 5 different layers of foam Each layer is having different cleaning efficiency After filtration the air goes to the turbocharger A HFM sensor is attached to the outlet of the air cleaner The air to the turbocharger has to go through the HFM The HFM measures the air mass going to the engine The quant...

Page 59: ...ol valve stuck in open condition 5 Boost pressure pipe hose assembly damaged 6 Turbocharger damaged Replace element Plug the leaks replace hose or clip if required Replace the hose or tighten Correct the control valve find the cause Check the pipe washer rectify Get the Turbocharger repaired at authorized TEL dealer Black smoke 1 Air intake restricted 2 Air leaks Check for hoses replace element Ch...

Page 60: ...it will lead to seepage of oil from turbocharger into the air intake system Ensure that the recommended engine oil only is used and the specified drain intervals are maintained To achieve an optimum cooling of the compressed air it is vital that the vehicle s number plate position is not changed and or an oversize number plate does not block the aperture for the air draft for the intercooler The T...

Page 61: ...ilter element Replace Air filter element at 40000 kms or early if required Do not attempt to Clean and reuse the Air filter element Air filter element to be replaced at every 40000kms or earlier in dusty conditions Nut Bolt description Quantity Nos Spanner Size Torque Value Nm Air filter top cover allen bolt Hose clamps air cleaner to manifold 07 02 02 6 mm 11 mm 11 mm 4 5 0 5 2 5 0 5 4 5 0 5 AIR ...

Page 62: ...the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs Following activities are covered under this section Air F...

Page 63: ...he Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Air Filter Assembly Removal 1 Using a 0 31 8mm socket and wrench set loosen the inlet hose lock clip screw A and detach the hose from the filter assembly B 2 Disconnect the HFM sensor from connection and position it aside 3 Remove the dirty ho...

Page 64: ... the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Turbocharger Assembly Removal Remove the air cleaner assembly Remove the exhaust pipe from after the elbow Access is only after lifting it on a two post or in a pit Remove the air intake hose to turbocharger Remove the oil feed pipe and the ...

Page 65: ...check should be done more thoroughly if any damage has been noticed in compressor or turbine blades as under normal operating conditions the blades can damaged only if a foreign object hits them Check all the hoses and pipes from turbocharger outlet to intercooler and intercooler to inlet manifold for crack aging leaks Check the hose clips for proper functioning If in doubt replace The oil supply ...

Page 66: ...e and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Air Filter Service Indicator Removal 1 Using a 0 67 17mm A open end spanner hold the service indicator B mounting on the intake hose and using a 0 43 11mm spanner C remove the service indicator Inspection 1 Check the service indicator for any physical damage Installation 1 To install reverse the removal procedure Clean Side I...

Page 67: ...n consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Dirty Side Hose Removal 1 Remove the clean side intake hose 2 Using a 0 31 8mm socket and wrench set loosen the dirty side intake ho...

Page 68: ...written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Intercooler Assembly Removal Intercooler assembly is fitted in the front of the radiator and condenser assembly inside front g...

Page 69: ...duction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the front gr...

Page 70: ...ized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Intake Manifold Removal Remove NVH cover Remove EGR assy Remove all high presser fuel lines CR assembly Remove Intake manifold assembly Removal the manifold gaskets as and when opened Check and correct leakage from EGR assembly or manifold mounting Exh...

Page 71: ...the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Turbocharger Assembly Removal Remove NVH cover intercooler assembly Remo...

Page 72: ...r is matched to give an optimum boost for the desired engine speed band A waste gate controls the boost The waste gate is used to bypass the excess exhaust gas away from the turbine and thus maintain the boost as well as control the backpressure A spring loaded diaphragm controls the waste gate A flap valve is installed in the turbine housing just before the turbine blade Opening the valve allows ...

Page 73: ...g of the actuator Check The inlet connection outlet exhaust connection to turbocharger for foreign material cracks blockages sand particles loose nuts etc This check should be done more thoroughly if any damage has been noticed in compressor or turbine blades as under normal operating conditions the blades can damaged only if a foreign object hits them Check all the hoses and pipes from turbocharg...

Page 74: ...bocharger Type K0 3 0088 M M k 03 2070 Turbocharger supplier Turbo Energy Ltd TEL Chennai Air velocity between the Air filter compressor inlet 35 M sec Air velocity between the compressor outlet and the inlet manifold 50 M Sec Max Maximum static back pressure at downstream of turbine 60 mbar Oil pressure at upstream of turbocharger 2 5 bar Description of system e g Charge pressure max power and to...

Page 75: ...n translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Cooling System Table o...

Page 76: ...Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Description The cooling system is designed to cater to the following functions Remove dissipate excess heat from the combustion process To maintain the optimum temperature for complete and uniform combustion To provide heating for the heater system In the models where the Heater is p...

Page 77: ...12 Mahindra Mahindra Ltd The functional system is shown in the block diagram Broadly speaking the water flows from the water pump to the Front cover from the cover it goes to cylinder block and from the block to the cylinder head and then to the bottom of thermostat In case the thermostat is closed water goes through the bypass tube to water pump Once the thermostat opens the water goes to the rad...

Page 78: ...d and from there to bottom of the thermostat One external pipe from the back end of the block goes to the oil cooler The return pipe form the oil cooler is connected to the inlet of the water pump Radiator No loss tank The radiator cap controls the system pressure to 0 9 bar Once the pressure exceeds 0 9 bar the cap lifts off the seat and the coolant is allowed to escape into a no loss tank As the...

Page 79: ...jams High speed Steep Gradients To avoid overheating under such conditions it will be worthwhile to Idle with the AC off In case the temperature indicator needle is close to the red band Increase the engine idling speed Symptom Causes Remedial action Noise Fan shroud 1 Fan contacting the shroud Water pump 1 Loose water pump impeller 2 Water pump bearing worn failure 3 Loose mounting of pump Belts ...

Page 80: ...ystem 4 Air trapped in system 5 Air in the system causing occasional burping 6 Faulty expansion bottle cap or pipe Allow the engine to run at idle for some time before stopping Find the area of leaks replace hose or if necessary the clamp also Pressure tests the system to check for leaks and then repair as necessary The flash may be visible by removing the cooling system components or the core plu...

Page 81: ...r Replace the gauge Coolant entry into Crankcase or cylinder 1 Low cylinder head torque 2 Faulty head gasket 3 Blow hole in crankcase head liner Replace the cylinder head gasket torque as per procedure Replace the cylinder head gasket Replace the affected part Low Temperature Gauge Indication Under cooling 1 Thermostat stuck open 2 Faulty sensor 3 Faulty gauge Replace thermostat Replace sensor Rep...

Page 82: ... in Cooling System COOLANT LEVEL LEAK INSPECT Coolant MAXIMILE Ultra Cool Pre mixed Capacity 8 0 Lit HIGH LOW COOLANT LEVEL INSPECT Refer illustrations shown Check the coolant level when the engine is cold Check the coolant level in the recovery tank 2 it should be between HIGH and LOW marks If below MIN top it up with Maximile Coolant Check the coolant level in the radiator 1 and top up if found ...

Page 83: ...EPLACE Refer illustrations shown A B and C 1 Open the radiator cap 2 Remove the drain plug on the Radiator bottom C and Engine block B 3 Drain the coolant and collect in drain tray 4 Refit the drain plugs fill new coolant in radiator 5 Check all the hoses clips for leakage and correct fitment 6 Start the engine and run at approx 1200rpm for 2 3 min 7 Check coolant level in radiator and add coolant...

Page 84: ...nd shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd ACCESSORY DRIVE BELT INSPECT Water Pump Alternator Drive Belt Belt Type Make 7 PK 1790 Gates HPHW belt ACCESSORY DRIVE BELT TO BE CHECK FOR Refer illustrations below 1 Abrasion 2 Cracking 3 Improper Install 4 Uneven Rib Wear 5 Misalignment 6 Chunk out 7 Gravel penetration 8 Pilling NEF 2 49L CRDe Accessory Drive Belts Misalignme...

Page 85: ... to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Inspect Accessory drive belts first at 5 000kms 10 000kms and then at every 10 000kms Replace it at every 80 000kms Inspect Power Steering drive belt at 5 000 20 000 kms and then at every 20 000kms Replace it at every 1 00 000 kms Uneven Rib Wear Belt shows damage to the side with the possibility of breaks ...

Page 86: ...or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs Following activities are covered in this sect...

Page 87: ...ra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd ACCESSORY BELT TENSION ADJUSTMENT 1 Check the Belt Tension Turn on the Belt Tension Gauge select reading mode in Hertz Hz hold the probe approximately 5mm distance in Front of the belt CAUTION Do not touch the probe to the belt this can damage the probe as shown in the illustration above b...

Page 88: ...e Make 7 PK 1790 Gates HPHW belt Nut Bolt description Quantity Nos Spanner Size Torque Value Nm Cooling Fan mtg nut 01 34 mm 45 05 Assembly Procedure Refer illustrations shown Checks drive belt condition before installing it Refer 900 MAT 0100 Align the drive belt with Water pump Alt Compressor pulleys Re tight manual tensioner assembly by tightening adjusting bolt 1 Check belt tension To be measu...

Page 89: ...thorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd IDLER TENSIONER BEARING INSPECT IDLER TENSIONER BEARING INSPECT Refer above illustration Bearings may complain the noise is usually speed specific Check if the noise varies according to the engine speed Check bearings for clicks rumbles and groans ...

Page 90: ...over Fan and shroud Remove Steering Pump drive belt Refer 900 MAT 0110 Loosen the Tensioner bolt to relieve the tension Loosen the Tensioner Pulley Nut Take out the pulley assembly with Dust Shield washer take the belt out Loosen the Idler Pulley Bolt Take out the pulley assembly with Dust Shield washer Remove the Circlip from the Tensioner Pulley Assembly take the bearing out Install the new bear...

Page 91: ...e for penalty prosecution 2012 Mahindra Mahindra Ltd Fan Blade viscous fan drive assembly removal Caution Do not remove the fan belt before removing the nut Loosen the water pump nut Note that the threads are anticlockwise threads Hence to loosen then the direction of rotation has to be clockwise when viewed from front The fan blade assembly and the VFD assembly can be removed together Water Pump ...

Page 92: ...thorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the HVAC return line from the water pump inlet Remove the hose connecting the oil cooler to the water pump Remove the water pump assembly after removing the mounting bolts While assembly ensure that the O ring is seated securely and does not...

Page 93: ...lation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the inlet and outlet h...

Page 94: ...used to circulate the coolant through the water jackets cylinder head hoses and radiator The water pump is belt driven by the engine main drive pulley It ratio of pulley diameter ensures that the water pump rotates 1 30 times the engine speed The water pump impeller is pressed onto the shaft The shaft is supported on two bearings that are integral to the shaft The water pump seal is located betwee...

Page 95: ...r and the fan will return to an idle condition Checking the VFD This procedure will only give an indication that the fan is cutting in and out but will not be able to check the accuracy of the cut in temperature Depending on the level of the test equipment there are several ways to check the if the fan is working correctly Using a non contact tachometer 1 Run the engine at idle without any load fo...

Page 96: ... the VFD Viscous Fan Drive The unit should be replaced While returning the failed unit to Plant for vehicles under warranty take care to see that the unit is packed with the sensing coil facing down and sent in the same way If this is not observed then the silicone fluid will flow down to bearing damaging the bearing and also making it impossible to do any investigation Viscous Fan Drive removal C...

Page 97: ... groove 1 Lack of tension 2 Misalignment of pulleys 3 Worn out pulleys 4 Excessive tension Adjust tension Correct the alignment Rib or belt wear 1 Pulley or pulley s mis aligned 2 Abrasive environment 3 Rusted pulley s 4 Sharp or jagged pulley groove tips 5 Poor surface finish Correct the alignment Clean pulleys replace if required Change pulley Replace belt Tooth shear 1 Low belt tension 2 Seizur...

Page 98: ...se Objectionable squeak squeal rumble heard or felt while drive belt is in operation 1 Belt slippage 2 Bearing noise 3 Belt mis alignment 4 Belt to pulley mismatch 5 Driven component induced vibration 6 System resonant frequency induced vibration Adjust belt Replace the defective bearing Adjust alignment Use the correct belt Vary belt tension within specifications Replace belt Tensile failure 1 Te...

Page 99: ...t speed of Fan pulley 1 30 x Engine speed Fan Belt tension New installation 165 2 Hz Stabilized 134 Hz Min Fan Belt tension Gates make New installation 170 5 Hz Stabilized 140 Hz Min Cooling system Liquid cooling system Nature of coolant liquid and capacity Ethylene Glycol based coolent water in ratio 30 70 Capacity 4 2 litr Only engine Characteristics of Circulating pump or make s type s Autolec ...

Page 100: ...ction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Fuel System Table ...

Page 101: ...including the High pressure pipes Return line from High Pressure Pump to tank The fuel is filled from the opening provided at rear left The fuel cap is ventilated and threaded type The cap is locked in place when further turning action result in clicking of the ratchet The fuel tank lid is electrically operated The switch is fitted on the centre bezel While filling the tank the air entrapped insid...

Page 102: ...dra Ltd Trouble Shooting Symptom Causes Remedial action Engine will not start emit black smoke 1 Clogged fuel filter fuel lines 2 Defective injectors Change fuel filter Check fuel supply line Refer diagnostic manual Noisy engine black smoke 1 Injector coking 2 CR System Clean external coking Refer the diagnostic manual Engine speed falls off 1 Clogged fuel filter fuel lines 2 Change fuel filter Ch...

Page 103: ...dra Ltd Care of the System The fuel injection system depends on supply of clean diesel fuel for the proper functioning of the fuel system To ensure that High Pressure Pump receives clean fuel all the times it is advisable that the fuel filter is replaced at the specified intervals The fuel filter should be changed at every 20 000 Kms If the operating conditions are poor then reduce the change inte...

Page 104: ... of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd FUEL FILTER ELEMENT REPLACE FUEL FILTER REPLACE Refer above illustrations shown Remove the Water in Fuel Sensor 2 at the bottom of the Fuel Filter element Remove the Fuel Filter Element 1 Fit a new fuel filter element and tighten it by hand 4 Refit the Water in fuel sens...

Page 105: ...y removing drain plug Ensure for complete fuel drain and Refit the drain plug 27 5 2 5 Nm Disconnect the fuel lines Main and return line hoses Disconnect the fuel filler hose and the breather hose Disconnect the tank unit connector Remove the fuel tank from the vehicle refer sketch Remove the Fuel Strainer with main line assembly by removing the fastening bolts Blow the compressed air gradually wi...

Page 106: ...rained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd FUEL FILTER DRAIN WATER SEDIMENTS FUEL FILTER DRAIN WATER SEDIMENTS Refer above illustrations 1 Loosen Water in Fuel Sensor at the bottom of the Fuel Filter by 2 turns 1 2 Allow the Water accumulated in the filter to drain...

Page 107: ...unt to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs The In Car repairs which can be carried out are Removal of Injectors Removal of High Pressure Pump Removal of Injector Loosen the high pressure pipes from both the common rail end injectors NOTE Avoid loosening only at one end as it can cause strain in the pipes while removing the injector...

Page 108: ...nt are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Removal of High Pressure Pump Remove tappet cover Bring the 1st cylinder in compression To...

Page 109: ... translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the HP Pump fron...

Page 110: ...m 70 C Fuel feed By fuel injection Injection system description Common Rail Direct Injection Working principle intake manifold direct injection injection pre chamber swirl chamber others Direct Injection Fuel Pump Make s and Country of origin if imported Bosch India HP Pump ECU Type Bosch CRS 2 2 CP1H with EDC 16C 1 Radial plunger High Pressure Pump Part ID No 0 445 010 131 2 Common Rail Part ID N...

Page 111: ...ehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahi...

Page 112: ...e tail pipe the EGR system adds exhaust gases into the fresh air that is going into the combustion chamber Since the exhaust gas is already burnt hence when mixed with fresh air acts an inert gas Thus when the exhaust gas mixed with fresh air enters the combustion chamber The role it does is that it reduces the amount of oxygen available for combustion The net effect is that it reduces the peak co...

Page 113: ...at if the rate of acceleration is above a certain level then the EGR will not operate This feature allows full engine power to be available during acceleration say during overtaking The Engine ECU controls the EGR The vacuum connections are shown below Working principle of Crankcase Ventilation System Functional blcok diagram of the Crankcase ventialtion is given below The ventilation system is cl...

Page 114: ...e joints 2 EGR pipe leak 3 EGR valve improper functioning 4 Vacuum hose crack loose fallen off Change the gasket or the hose Change the pipe Check the EGR using the blink codes Proceed appropriately Ensure vacuum connections at vacuum modulator reservoir and alternator Noisy engine high smoke 1 Cylinder head gasket defective 2 Worn out or damaged valve seats 3 Leaking injector pipe HP pipe 4 Leaka...

Page 115: ... black soot indicates leakage Check the vacuum hoses for any leaks cracks Retighten all nuts and bolts as per the recommend torque If the pipes are removed then it is essential that while fitting back new gaskets is used Do not open the pipe from one end only it will cause the pipe to twist If the EGR pipe has to be removed then open from both the ends The EGR operation is controlling by Engine EC...

Page 116: ...n 2012 Mahindra Mahindra Ltd EGR Cooler EGR cooler does not require any maintenance During coolant level leak check as well as refilling it is recommended to check for any leak at the EGR cooler coolant inlet and outlet hose connections Tight the clamps and arrest the coolant leakages if any ECU It does not require any maintenance However like any ECU care has to be taken that if any welding work ...

Page 117: ...m which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecut...

Page 118: ... prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd EGR Valve Removal Nut Bolt description Quantity Nos Spanner Size Torque Value Nm EGR valve assembly mtg bolts 04 12 mm ...

Page 119: ...ce gasket while assembling g EGR pipe TC to EGR Valve Check and top up the coolant level in radiator reservoir EGR Cooler is only applicable for BS IV engines Nut Bolt description Quantity Nos Spanner Size Torque Value Nm EGR pipe mtg bracket bolt EGR pipe mtg allen bolt exh side EGR pipe mtg on valve body EGR valve body on intake manifold 01 02 02 04 12 mm 05 mm 12 mm 12 mm 25 03 25 03 25 03 25 0...

Page 120: ...roprietary Part No if not proprietary Part No 0903AAA08370N Internal dia of exhaust pipe mm 57 1 Minimum distance between exhaust pipe s and the fuel line 160 mm Catalyser make number and Country of origin ECOCAT India Private Limited Coater ECOCAT India Private Limited Canner ECOCAT India Private Limited opt Tenneco Exhaust India Opt Sharada Motors India Identification Mark Part No 0902AA0430N Op...

Page 121: ...duction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Clutch Table of Con...

Page 122: ...utch disc is used In the engaged position when the clutch pedal is not pressed the diaphragm spring of the clutch cover assembly holds the clutch pressure plate against the clutch disc This enables the engine torque to be transmitted to the input shaft of the gearbox without any slip loss The clutch is hydraulically actuated with self adjusting features The complete actuation system comprises of a...

Page 123: ...any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Care of the System While topping up use the recommended fluid conforming to DOT 3 specifications only Avoid mixing different brands The clutch fluid is hygroscopic fluids hence tend to collect hu...

Page 124: ...CH FLUID LEVEL LEAK INSPECT Clutch Fluid DOT3 standard SAE J103 IS 8654 Park the vehicle on level ground 2 post lift 4 post lift Always use recommended fluids only Do not mix different brand fluids Clutch fluid to be replaced at every 40000kms If the activity is done on a 2 post lift ensure that the LSPV spring is disconnected before lifting the vehicle After lowering re connect the LSPV spring an...

Page 125: ...vity is done on a 2 post lift ensure that the LSPV spring is disconnected before lifting the vehicle re connect the LSPV spring ensure that the setting height is correct after job complete CLUTCH FLUID REPLACE Refer above illustration Remove the dust cap of the bleeder screw If the bleeding operation is done without connecting a tube and in the open air then the chance of air remaining trapped is ...

Page 126: ...fully pressed slowly apply the brake with your left feet If the engine stalls then the clutch is not slipping Clutch Problem Causes Fluid contamination is the most frequent cause of clutch malfunction Oil water on the clutch contact surface will cause faulty operation viz Slip grab and judder During inspection check if any parts in the clutch are coated with oil or water splash from road Oil conta...

Page 127: ...ust be tightened alternatively diagonal pattern and evenly i e 2 to 3 thread a time only A noisy gearshift operation especially the 1st and 2nd gear can be due to clutch not getting disengaged completely To check it jack up the rear axle Lift the axle till both the wheels are rotating freely Press the clutch pedal completely and start the engine the wheels should not be spinning Now slowly release...

Page 128: ... at 1 Crankshaft rear end oil seal 2 Leak through the input shaft 3 Excess amount of grease applied to the input shaft splines Replace seal disc Clean cover assembly Replace seal disc Clean cover assembly Apply less grease Replace clutch disc Clean cover assembly Clutch is running partially disengaged Release bearing carrier sticky Replace bearing carrier Flywheel height incorrect 1 Improperly mac...

Page 129: ...rd parts 2 Improper tightening or loosening procedure 3 Rough handling of clutch plate or cover assembly Replace disc and cover with the correct parts Replace the parts and tighten as per sequence Replace the parts ensure that the rough handling is avoided Partial engagements of clutch disc One side worn opposite side glazed and lightly worn 1 Clutch pressure plate position setting incorrect or mo...

Page 130: ...t shaft Replace the clutch plate Replace input shaft is severely damaged Replace the clutch plate Replace the input shaft if the scaling can not be removed Clutch disc facing sticks to flywheel Vacuum may form in pockets over rivet head Occurs as clutch cools down after use Drill 1 16 inch diameter hole through rivets and scuff sand the clutch disc facing Clutch will not disengage properly 1 Low f...

Page 131: ... prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs Adjustment of clutch pedal height Loosen the lock nut of master cylinder s push rod fork Slide backs the...

Page 132: ...rsonnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd the pedal lever release pedal Screw out the bolt further by one turn Tighten the locknut Recheck pedal height Bleeding the clutch Clean the external areas of the clutch slave cylinder and remove the dust cap of the bleeder screw If...

Page 133: ...e use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Operate clutch pedal 3 or 4 times slowly to the full stroke Holding the clutch in depressed condition loosen the bleeding screw on slave cylinder by to turn and allow al...

Page 134: ...Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Clutch Actuation Mechanism The clutch actuation is hydraulic actuation The clutch pedal actuates a master cylinder The hydraulic fluid is transmi...

Page 135: ...ction translation transmission in part or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Master cylinder overh...

Page 136: ...n the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 1 Pull back the dust cover 2 Remove circlip 3 Remove the push rod assembly with retainer washer 4 Remove the piston assembly by gently tapping the Clutch Master cylinder body on a wooden block Using a screwdriver li...

Page 137: ...dra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd While assembling hold the spacer between fingers such that the valve stems hangs down vertically Pull down the stem downwards as far as possible Observe if the valve stem has moved freely upwards If movement is not free replace valve spacer Remove the valve seal from the valve stem The bo...

Page 138: ...ther than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 1 Remove dust cover 2 Remove circlip 3 Remove plunger with gland seal and plunger spring from body by lightly tapping it on wooden block 4 Remove gland seal from plunger The bore and the plunger should be ch...

Page 139: ...a Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Clutch overhaul Block the front wheels so that the vehicle does not move forward Disconnect the negative cable of the battery Remove the electrical connections t...

Page 140: ...emove the gearbox mounting insulators Remove the clutch housing mounting screws to the engine rear face the ladder frame Move the gearbox away from the engine Remove the clutch release bearing with sleeve Remove the clutch fork If the original cover will be reinstalled then mark position of cover on the flywheel for assembly reference Use paint as a marker for this If the cover assembly may be reu...

Page 141: ...and grease present on the mounting face it can cause cocking run out The flywheel bolts have been replaced Torque tightened as per sequence and also the angular tightening as per the specification is done Absence of any of these requirements may result in bolt loosening causing flywheel runout Clutch cover Disc runout Check the clutch disc runout before fitting It should be within the specificatio...

Page 142: ...ut is 0 076 mm If scoring is deeper than 0 0076 mm then the flywheel has to be changed Excessive material removal will cause the flywheel to either crack war page after installation drop in clamping load and will affect the proper clutch release as the travel of release bearing gets affected If the flywheel has been removed for resurfacing or replacing the pilot bearing then while fitting it back ...

Page 143: ... of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Technical Specifications Figure Description Value Clutch control type Hydraulic self adjusting Pressure plate Diaphragm Clutch Disc Outer Dia mm Inner Dia mm 240 1 160 1 Disc...

Page 144: ...be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Master Cylinder Bore diameter 19 05 mm Slave Cylinder Inner diameter 22 22 mm Clearance between The piston the bore Both cylinders 0 13 mm Flywheel Flatness Runout Standard Service Limit 0 05 0 1 0 05 0 1 Flywheel Width from Mounting face to clutch face 35 0 13 Clutch release point from pedal full stroke end position 25 mm from Bottom po...

Page 145: ...cument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd List of the MST Description Part No Sketch Usage View Master clutch plate assembly die...

Page 146: ... whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Transmission NGT530R Table of Content Description Trouble Shoo...

Page 147: ...ver tongue operating in a 3 rail system The accidental operation of two gears is avoided by an interlocking mechanism To avoid vibrations passing on to the shift lever the shift lever is a two piece with rubber isolation provided on to the top half The gearbox housing is 3 piece aluminium with an intermediate plate A skid plate protects the bottom of the gear box The Gearbox is mounted directly on...

Page 148: ...present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Specification Transmission 4WD Cross sectional View SHIFT LEVER INTERMEDIATE...

Page 149: ...evel check can be made only when the vehicle is level use a two post or a four post hoist to ensure this Also allow the lubricant to settle for a minute or so before checking These recommendations will ensure that an accurate check and avoid an under fill or overfill conditions Hard Shifting Hard shifting is usually caused by low lubricant level improper or contaminated lubricants component damage...

Page 150: ...d locate how the foreign matter came inside e g missing breather and rectify that also to avoid recurrence Replace the bearings Jumping out of gear Defective detent springs Worn out grooves in shift rail Shaft misalignment Worn dog teeth in gear Worn out fork fork pads Worn out synchronizer body Gear lever fouling Bottom lever slot worn out Replace the detent springs Replace the shift rails Check ...

Page 151: ...at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Procedure to diagnose concern of reverse gear lock Step 1 Confirm concern of gear lock in reverse gear or gear lever is not coming to neutral position After confirmation of the concern remove Transmission from the vehicle Refer SOP Step 2 ...

Page 152: ... present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Step 5 Remove rear housing carefully Take care that rear end oil seal and b...

Page 153: ...nt of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Step 9 Take new Sub Shaft Hub Assembly Part No 0703DAD06050N for NGT 530R Transmission Step 10 If Synchroniser Ring or Key Found Damaged Re...

Page 154: ...esent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Step 13 Assemble the 5th drive gear assembly on to the 5th Reverse sub shaft S...

Page 155: ... written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Step 17 Apply loctite 574 on the mating surface of the rear housing Assemble rear housing on to the intermediate housing Step...

Page 156: ...nsmission are 1 8 to 2 Liters TRANSMISSION OIL Replacement Procedure Transmission Oil Replace Refer above illustration 1 Remove the Filler plug 2 Put the oil collection tray under transmission Remove the drain plug Allow the oil to drain out completely 3 Clean the metal particles if any deposited on the drain plug Assemble torque tight the drain plug with new washer 27 5 2 5 Nm 4 Fill fresh transm...

Page 157: ... prosecution 2012 Mahindra Mahindra Ltd Rear Oil Seal Replacement 2WD Follow below step If the Transmission assembly is not removed from the vehicle Remove the Rear propeller shaft from the transmission end Only front end of rear propeller shaft to be removed in case of 2WD vehicle Refer section removal and installation of propeller shaft for more information The rear oil seal is fitted at the rea...

Page 158: ...nt by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Gear Position Gear Neutral Switch Check If the vehicle is equipped with Engine Stop Start feature follow the procedure given below Micro hybrid vehicles are equipped with STOP START system ...

Page 159: ...he Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repairs Transmission Removal Before separating the transmission from the engine remove the crankshaft position sensor OBD from the clutch housing if applicable Support transmission while removing it from vehicle Remove battery ve termin...

Page 160: ...ent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In case of Concentric Slave Cylinder Remove the Clutch fluid line from the quick fix joint NOTE Put a tray below to avoid clutch fluid see...

Page 161: ...Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove Rear propeller shaft and Remove front propeller shaft in case of 4WD vehicle Remove gear knob and shift lever upper part Remove insulator below TM and the Cross member below the TM assembly CAUTION Support to the TM assembly bottom side for safety purpose an...

Page 162: ...ocument by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Put tray below the transfer case remove the oil drain plug and drain the Transfer Case oil If required This is required in case of system overhaul In case of 4WD with BW Electric Shift...

Page 163: ... vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Ma...

Page 164: ... manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahind...

Page 165: ...units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be li...

Page 166: ...ous component units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use a...

Page 167: ...le of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Shift Rail and Shift Fork Assembly Sectional View A 1st 2nd fork b...

Page 168: ...d accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for...

Page 169: ...the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012...

Page 170: ...d personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove Clutch release bearing and fork if applicable NOTE Ignore this step if vehicle is fitted with Concentric Slave Cylinder If vehicle is fitted with Concentric Slave Cylinder Remove the Clutch fluid line from the quick fix ...

Page 171: ...tion transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Use a lengthy screw driver and ...

Page 172: ...Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Use mallet to remove dust cover if it is jam Avoid damage to the dust cover which will not allow proper fitment Remove rear housing mounting bolts Ensure removal o...

Page 173: ...d The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remov...

Page 174: ...h the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 20...

Page 175: ...ction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the counter...

Page 176: ...ranslation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove the drive shaft fr...

Page 177: ...prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Reverse gear fork to be taken forward and remove Circlip and bearing using puller Remove 5th driv...

Page 178: ...vice Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Remove poppet plug fitted on intermediate plate and shaft rail assembly of 5th and reverse Be careful not to lose ball spring while removing shaft and rail assembly NOTE It is differ as in 2WD and 4WD Output shaft in 4WD provided with lock nut where as in 2WD ...

Page 179: ...e use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Inspect Lock pins for reuse Keep lock pins safely if found ok it is recommended to replace lock pins if it is not found in usable condition 4WD output shaft having splin...

Page 180: ...cument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Take out reverse gear from output shaft Separate drive shaft from intermediate plate N...

Page 181: ...production translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Main Shaft Dr...

Page 182: ...resent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Transmission Components Inspection 1 Shift Control Rod and Fork Inspection Ch...

Page 183: ...the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 3 Synchronizers Check splines portion of coupling sleeves synchronizer h...

Page 184: ...ution 2012 Mahindra Mahindra Ltd Transmission Components 0Assembly Assembly of the Transmission is the reverse of its disassembly While assembling following care should be taken Ensure that front housing intermediate plate and all components are free from dirt dust before assembling Transmission bearings life will reduce in case use of unclean gear components used Assembling Synchronizers Strut ty...

Page 185: ...d shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Press bearing to the full depth Maintain runout of counter sub shaft within 0 05 mm extended countershaft with subshaft Mark counter sub shaft with marker on spline end for matching at which the runout is within specification If run out in counter sub shaft pairing is not maintained then 5th gear slippage can take place MD Gear A...

Page 186: ...Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Rear Housing Sub Assembly Assemble the drain plug and tight it to 25 30 Nm Refer illustration Press the Oil seal and bearing outer race Fit the circlip into the re...

Page 187: ...brass ring to MD gear Make sure that output shaft and MD gear are free to rotate Keep intermediate plate over counter and output shaft Assemble the reverse driven and idler gear Check and ensure that circlip is not having axial play Check dimple mark on 1st 2nd shift rail before using it for assembly Refer illustration Apply loctite on Front Rear housing joint Face with Loctite robo 7192 If retain...

Page 188: ... if split pin is not pressed Crash shifting will happen if split pin is fouling If there is no rail end gap it may foul and make hard shifting complaint 5th DRIVING DRIVEN GEAR ASSEMBLY Keep roller bearing on 5th driven gear ensure that cone is downward side Ensure that brass ring is placed below the 5th driving gear Match 5th gear tooth and press the gears Ensure output shaft sleeve free rotation...

Page 189: ...ra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd CLUTCH HSG SUB ASSEMBLY OIL SEAL PRESSING Ensure Proper placement of clutch housing Ensure fitment of ball stud before fitment of sleeve thrust bearing Ensure fitment of circlip after proper pressing of Sleeve thrust bearing Ensure ball stud torque 17 22 Nm Ensure proper application of sea...

Page 190: ...ritten consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Place bottom grommet over pivot Place circlip over bottom grommet with its grove facing towards 1st 2nd biasing as shown in pic...

Page 191: ... penalty prosecution 2012 Mahindra Mahindra Ltd Assemble Bearing retainer plate by tightening its mounting bolts NOTE Put Anabond 111 to the 6 nos M8 size mounting bolts CAUTION Ensure counter shaft bearing is pressed such that bearing should be flushing with the rear face of the plate Ensure torque on M10 bolts for idler shaft Torque value 43 7 Nm NOTE If Wire ring is not fitted properly then it ...

Page 192: ...ransmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Insert three struts Small length on r...

Page 193: ...ocument by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Rotate entire assembly on opposite side i e 5th side fix the C SPRING Check the entire assembly for the fitment Use Double DOP hub having groove on OD In case synchro key is missing or...

Page 194: ...t the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Double Cone Synchronizer Double cone synchronizer consists of Hub sleeve struts inner ring outer ring and intermed...

Page 195: ...ined personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd NOTE Be careful struts should not jump out of ring causes injury Place outer ring on the hub by engaging ring s projections in to hub pockets Place intermediate ring as shown in the picture three tang should come in front of...

Page 196: ... amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Please ensure other synchronizer assembly remains in the same position Invert the above whole assembly and put on to the Gear box shaft Put outer ring intermediate ring inner ring and 2ndgear as described above Refer illustration of full double cone assembly 1st 2nd Speedo Sleeve Sub Assembly CAUTION...

Page 197: ... Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Wrong use of lever spring causes to lever rattling Wrong direction of bottom grommet circlip causes leakage from grommet After adaptor dowel fitment put the adaptor pivot on fixture assembly table NOTE If pivot not entering s a fixture fully then check whether the...

Page 198: ... any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Assemble the nylon bush spring and retension plate Refer illustartions NOTE Ensure bush fittment In case bush is missing improper shifting or lever rattling may occur After placing retension pla...

Page 199: ...esent document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Torque the side cover bolts to the torque value 8 2 Nm Lever Fittment Apply in...

Page 200: ...er than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Ensure proper location of pivot assy with help of dowel Pivot pin facing downwards Fit pivot pin with pivot insertion pressing impactor dolly Apply silicon sealant on pivot Fit pivot by tapping it Use new Rubb...

Page 201: ...sensor while fitting to ensure gap 6 mm between them Fit the Allen screw with help of screw driver apply 2 5 0 5 Nm torque Fit the grommet on pivot Assembly Inspection Make sure that the following check points to be carried out after completion of Transmission assembly and before fitting it on vehicle Check for presence of railed caps Check for presence of breather Check for static shifting Check ...

Page 202: ...uthorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Technical Specification Figure Description Value Type Mechanical Description NGT 530 R Gears 5 Forward and one reverse gear Gear shift Direct shift with rubberized lever Gears Helical toothed 1 3 5 2 4 R Gear Engagement Block synchro ring type syn...

Page 203: ... Hsg Loctite 510 4 Breather Anabond 413 Retaining Grade 5 Pivot locking RTV Sealant Metlock 920 Option 1 Rhodorseal Option 2 Pidiseal 3P 6 Between Clutch Hsg OD of Ft Bearing Retainer Loctite 510 7 Clutch Release Bearing support sleeve Loctite 510 8 Poppet Plug M 12X1 25 Loctite 542 Tightening Sequence Description Torque in Nm Transmission decking with engine 80 10Nm Tee 3 way assembly to gear car...

Page 204: ...he reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd List of ...

Page 205: ...which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecutio...

Page 206: ...hich the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution...

Page 207: ...essories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for pena...

Page 208: ...nsmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Transfer Case BW Table of Content Descr...

Page 209: ... with the power input The power received by the input shaft and is coupled to the two output shafts of the transfer case One of the output shafts is fixed to the rear axle and other is fixed to the front axle The planetary gear set provides gear reduction The power is transferred to the front wheel drive through a Morse HY VO chain drive The oil pump provides lubrication to the planetary gear set ...

Page 210: ...heels are driven at 1 1 speed ratio The four wheel drive lamp illuminates when 4H mode is selected This mode provides additional traction and maximum pulling power for loose slippery road surfaces such as ice snow gravel sand and dry pavement Front and rear drive shafts are locked together in this mode which forces the front and rear wheels to rotate at the same speed 4L Four Wheel Low All four wh...

Page 211: ...rating or decelerating or drive forward and backward in a short distance If the lamp continues to illuminate contact an authorized Mahindra USA dealer as soon as possible There may be a malfunction in your four wheel drive system Your vehicle is equipped to shift from 2H to 4H mode at any vehicle speed from 0 60 mph To shift from 2H to 4H turn the selector switch to 4H position Once the shifting i...

Page 212: ...ndra Mahindra Ltd Shifting from 4H to 4L Bring the vehicle to a complete stop with the brake pedal depressed Shift the TGS lever into N Neutral Turn the four wheel drive selector switch to 4L position 4WD LOW lamp in the cluster should illuminate and 4WD HIGH lamp goes out If 4WD LOW lamp doesn t illuminate within 10 sec Repeat the above steps again Shifting from 4L to 4H Bring the vehicle to a co...

Page 213: ...ear and shift motor for any damage Check for loose mounting bolts Electrical Check for any damage and continuity in the transfer case wiring harness Check for malfunction of the transfer case module and 2W 4W change switches Troubleshooting Chart Symptom Possible Causes Remedy No front wheel drive when shifted to 4WD 1 Broken drive chain link age 2 Shift motor faulty 3 Selection switch faulty 4 TC...

Page 214: ... ensure proper application 6 Replace the oil seal Electronic shift problems 1 Faulty or damaged TC CU speed sensor clutch or internal wiring 2 Damaged or worn shift cam hub fork or rail shaft 3 2W 4W shift motor malfunction 1 For additional information refer to MDS 2 Disassemble the transfer case and check for wear and damage Replace the necessary parts 3 Check and replace the shift mo tor if nece...

Page 215: ...thorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd In Car Repair Removal 1 Disconnect and isolate the negative terminal of the battery 2 Raise and support the vehicle 3 Disconnect the wiring harness connection from the transfer case 4 Disconnect the front and rear propeller shafts from the transfer...

Page 216: ... prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 9 To install reverse the removal procedure 10 Tighten all bolts and nuts to the specified torque 11 Using a suitable sp...

Page 217: ... consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 14 Using a suitable spanner tighten the oil filling plug A in the transfer case Disassembly 1 Position the transfer case on the repai...

Page 218: ...oduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 3 Separate the ...

Page 219: ...ansmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 6 Using a suitable flat screw driver r...

Page 220: ...ed without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 9 Gently pull and detach the sensor from the rear casing To avoid damage of the metal surface apply limit...

Page 221: ...nslation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 12 Separate the return spri...

Page 222: ... The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 15 Det...

Page 223: ...e of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 18 Using a MST pull out the needle bearing A from the rear casing c...

Page 224: ...red The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 21 ...

Page 225: ... reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 24 Separat...

Page 226: ...ranslation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 27 Unlock the clip E and ...

Page 227: ...ufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra L...

Page 228: ...r whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 33 Unlock the snap ring A and remove the bearing B 34 Using a...

Page 229: ...roduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 36 Remove the ...

Page 230: ...factured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Lt...

Page 231: ...anslation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 42 Remove the sun gear thr...

Page 232: ...Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Inspection 1 Visually check all the parts for any damage and distortion 2 Check the magnet for the presence of any metal particles which indicates internal damage of the transfer case parts 3 Referring to normal gear tooth face specifically inspect the uneven wear chips of gear tooth and bear...

Page 233: ...ther than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 3 Install the input shaft A into the front casing Check the oil seal prior to installation In case of any external damages are observed and then replace the oil seal 4 Using a MST install an oil seal A into ...

Page 234: ...ion translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 6 Install the needle...

Page 235: ...of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 9 Install the thrust plate to the input shaft 10 Using a ...

Page 236: ...f the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 12 Install the adapter input shaft and carrier assembly to the case an...

Page 237: ...he prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 15 Using the MST yoke holder A socket and wrench set B and torque wrench tighten the front flange mounting lock nut t...

Page 238: ...he reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 18 Insta...

Page 239: ...e prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 21 Align the gear rotor pump with the output shaft Align the guide pin of the shaft to the slot...

Page 240: ...he prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 24 Install the driven sprocket A on the front output shaft end 25 Install the drive chain A onto the sprocket Holding...

Page 241: ...cument are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 27 Install the 2W 4W lock up fork A the clutch plate B and the clutch housing C to the...

Page 242: ...whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 30 Install the return spring A over rail shaft in the transfer ...

Page 243: ...Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 33 Tighten the coil mounting nut A to specified torque 34 Apply a 0 06 1 6mm bead of loctite RTV598 to the transfer case mounting surface A Align both the...

Page 244: ...n part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 36 Install the Speedo gear output shaft spline in ...

Page 245: ...t document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 39 Insert the sensor A into its position 40 Apply a 0 06 1 6mm bead of loctite RTV...

Page 246: ...he present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 42 Assemble the Speedo driven gear shaft B and Speedo body A 43 Install t...

Page 247: ... translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 45 Using the MST tighte...

Page 248: ...s and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable...

Page 249: ...lt codes in binary Connect one end to the pin whole number 9 in ECU connector and other end to the ignition switch The flashing of indicator light will show the defective code as illustrated in the table Identify the malfunctioning part and replace it L1 L2 L3 Binary Code Decimal Equivalent Fault With Off Off On 001 1 ECU Module Off On Off 010 2 Shifter Motor Off On On 011 3 Synchronizer Clutch On...

Page 250: ...units and accessories from which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be li...

Page 251: ... the drag sleeve 26 fit over the tangs on the washer preventing the drag sleeve from rotating The brake band 24 fits over the serrated portion of the drag sleeve The tangs of the brake band are fitted through the window in the steel inner cage 21 The plastic outer cage 20 fits over the inner cage Each tang of the brake band fits through each cut out in the outer cage The cam follower 19 is attache...

Page 252: ... engaged and vehicle starts to move the axle shaft starts to turn the hub sleeve 16 clutch gear 15 and cam follower 19 The steel inner cage 21 And plastic outer cage 20 also start to turn Remember the drag sleeve 26 is fixed to the wheel spindle and doesn t rotate When the inner cage window hits the first brake band tang 30 the band tightens up on the drag sleeve This stops the inner cage The cam ...

Page 253: ... A broken or missing washer will allow the drag sleeve to rotate with the brake band If the hub is not engaged the brake band is unable to lock on the drag sleeve and initiate the locking action of the clutches If the hubs are engaged the brake band cannot be released to allow the clutch gear to disengage A broken or missing brake band cannot lock the inner cage to engage the hub or be unlocked by...

Page 254: ... which the vehicles are manufactured The reproduction translation transmission in part of or whole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecuti...

Page 255: ... engaging with the 4 tanged washer Install the Hub Lock in the wheel hub 3 Rotate the Hub Lock to match the threaded holes of the wheel hub Put 6 nos bolts face to face 4 Tighten 6 nos bolts with the help of special Allen key to 5 5 to 6 5 kg m torque using Torque Wrench 5 Tight the end cap with the help of pin spanner Disassembly of Automatic Locking Hub 1 Remove the end cap and bearing race spri...

Page 256: ... out of the large groove in the outer clutch housing 7 Hold the lug and go on to the next one It s easiest to start with the lugs opposite the one that fits into the window of the steel inner cage 8 Slide the cam follower assembly out of the outer clutch housing Cleaning 1 Using a cleaning solvent clean the all the parts except DRAGE SLEEVE since it is permanently lubricated with Darmex grease 2 A...

Page 257: ...fter 2 wheel drive is selected the faulty hub transmits the wheel rotation to the axle shaft The mechanical situation is like a conventional axle raised off the ground The axle shaft drives the differential pinions through the side gear The ring gear and cage are not turning so the other side gear and axle shaft are driven in the opposite direction to the first one The axle shaft tries to engage t...

Page 258: ...dra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 3 Install the plastic outer cage into the large groove in the outer clutch housing The cage may be easier to install if the tangs on the each side of the cutout are installed first 4 Install the steel inner cage inside the plastic outer cage For clarity the cages on the right are...

Page 259: ...ole of the present document are prohibited without the prior written consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd 7 Install the snap ring to the hub sleeve 8 Install the outer bea...

Page 260: ...of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd Technical Specification Description Specification Configuration Part time Single Offset Rear output configuration Circular flange Front output configuration Fixed yoke Input configuration Female spline Offset hand Right hand Lubrication System Force lubrication by Gear ro...

Page 261: ...consent of Mahindra Mahindra Ltd The use of this document by any person other than the trained personnel at the Authorized Service Centre of Mahindra Mahindra Ltd will amount to unauthorized use and shall be liable for penalty prosecution 2012 Mahindra Mahindra Ltd List of Special Tools MST Description Borg Warner Part No Yoke Holder 1 T 10001 Seal Driver T 10003 Snap Ring Plier Adapter 3 T 10007 ...

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