India’s first Mahindra Bolero BS6 to get aftermarket 4×4 system

Mahindra Bolero is one the oldest model from the manufacturer. It has been in production for over 2 decades and is still popular among buyers for its rugged looks and utilitarian design. Mahindra used to offer a 4×4 version of Bolero in the market but, it was discontinued from the market at a later stage. There are several examples of modified and well maintained 4×4 Mahindra Bolero SUVs in different parts of the country. Over the years, Mahindra made necessary changes to keep it compliant with the new emission and safety norms. We currently have the BS6 version of Bolero in the market which is available as a 2WD SUV. Here we have a video that shows a Mahindra Bolero BS6 that gets an aftermarket 4WD setup installed in it.

The video has been installed by Vivek Dewanta on his YouTube channel. This is probably the first and only Mahindra Bolero BS6 in the country to get a 4×4 set up. In this video, owner talks about all the modifications and the challenges that he faced while converting a 2WD SUV to a 4WD.

He starts with the exteriors. The main modification here are the wheels. The stock 15 inch steel rims on Mahindra Bolero were replaces with 16 inch aftermarket wheels with chunkier All-Terrain tyres. As the tyres were now wider than the stock units, the owner had to install a fender flare to protect the body from mud. Mud flaps have also been installed in this Bolero.

Coming to the mechanical changes, the main modification is the addition of 4×4 system to the SUV. The owner mentions that he initially had plans to install a manual gear lever but, later he discovered that the 4×4 lever would have come in the way of operating clutch. Then he decided to go for an electronic shifter similar to what was available in Scorpio 4WD.

India’s first Mahindra Bolero BS6 to get aftermarket 4×4 system

The Bolero can currently be used in 2H and 4 Low. 4 high is currently not engaging and owner said, he can manage without 4H. He then starts talking about all the challenges that he faced during this modification. The main issue was sourcing the components. As Mahindra does not offer 4×4 Bolero in the market anymore, it was difficult task. Once the parts where sourced, installation was another challenge in itself.

The original crossmember in the Bolero BS6 was removed and made modification to the chassis to accommodate the 4×4 system, gearbox and engine. The owner said it took him more than 7 months to convert this 2WD Bolero to 4WD. Owner mentions that all the modifications that he has done to the Bolero have made the company warranty of the car void. He does not recommend doing such modifications but, if you really want to modify a Bolero then it must be done on their own risk.

Another issue with this modification is that it cannot be changed from 2WD Bolero to 4WD Bolero and Mahindra does not offer a 4×4 BS6 verison of the Bolero in the market. The engine on this Mahindra Bolero is a 1.5 litre turbocharged engine that generates 76 Ps and 210 nm of peak torque.