Mahindra Thar Modification

The Mahindra Thar has made quite an impact on the Indian automotive scene thanks to its retro looks that back to the days of old school jeeps. The Thar attempts to put an end to all that. This is a vehicle that has the goal to deliver enthusiasts from their misery and bring them closer to getting muddier, slushier and rockier without the added stress of making do with old equipment. Here is an attempt to modifiy or upgrade Thar from the core. Following information are collected and put together from various sources from TeamBhp forum. Thar CRDe brakes are derived out of old Scorpio / Bolero VLX (withNEF engine). All parts required to upgrade are in existence. The interchangeability of parts needs to as follows. This information is indicative.

 

Stub axle assembly RH and LH   

1. 10” single stage booster as in production Thar CRDe, derived out of Scorpio M2DI.
2. Tandem booster with master cylinder, same as Bolero VLX.
3. Mounting dimensions match exactly including push rod length. Brake pedal does not require any change. Bundy pipes and vacuum hose may need minor repositioning due to extra dimension in longitudinal axis but no change in design length for field fix.

Stub axle assembly RH and LH 

1. Production Thar CRDe, derived out of post May 2003 but pre-2005 Scorpio 4WD non-CRDe base model (steering gear was moved towards the front in Scorpio in 2003. Suspension was reinforced by adding a cross member.
2. Post 2005 production Scorpio CRDe 4WD with NEF engine and 16” tires, with Bosch Chassis Systems suitability of Brake Assembly without ABS.
3. Upper and lower ball joint location is interchangeable. Caster is common for 2WD / 4WD (2 degrees 45 minutes nominal). 

Brake disc and hub assembly RH and LH

1. Production Thar CRDe, derived out of post May 2003 but pre-2005 Scorpio 4WD non-CRDe base model
2. Post 2005 production Scorpio CRDe 4WD with NEF engine and 16” tires, with Bosch Chassis Systems Brake without ABS.
3. Mounting is exactly same as Scorpio 4WD. 

Caliper assembly RH and LH

1. Single pot caliper, production Thar CRDe, derived out of pre-2005 Scorpio 4WD non-CRDe base model.
2. Twin pot caliper, post 2005 production Scorpio CRDe 4WD with NEF engine and 16” tires, with Bosch Chassis Systems Brake without ABS.
3. Mounting is exactly same as Scorpio 4WD. 

Steel wheel and tire assembly

No change required but only 16” and above size can be used. 15" wheel cannot be used with twin pot caliper installation. No deviation on inset. Production value is +55 mm.

 

Minor deviation on LSPV setting may or may not be required, to be conducted on case to case basis. Add brake fluid quantity as necessary for twin pot calipers.

 

You need to be careful at dealerships on part numbers. There will be numerous part numbers of same looking parts (e.g. with and without ABS, BI v/s Bosch etc). Please obtain all correct parts, please cross check in the relevant parts catalogues before dismantling the vehicle.