1973 FJ40 SM465 Swap (2 Viewers)

[Mopdog]

Well, the question is obvious. Do you still have it?

No, I gave it to a guy with the same problem years ago.

 

[Mopdog]

So here’s a thought, probably a dumb one...since there’s a 9/16” hole drilled in it, what if I welded the $&@! out of a 9/16” bolt with the top cut off into the hole? It would essentially make it a stud that I could put a locking nut on. Is that a crazy idea?

I’m not a mechanic or an engineer but you might be onto something there.

 

[archie73]

I’m not a mechanic or an engineer but you might be onto something there.

One thought before you weld it make sure it’s gonna hold. One of the inner mounting bolts fell into my old Tcase gears and put a quarter sized hole in the case. This is my fault no doubt, but the moral of the story is make sure that bolt isn’t coming out or you’ll be shopping for an Orion. Of course this was a good excuse to upgrade and I do love the sm465/4:1 combo.

 

[SC Forester]

One thought before you weld it make sure it’s gonna hold. One of the inner mounting bolts fell into my old Tcase gears and put a quarter sized hole in the case. This is my fault no doubt, but the moral of the story is make sure that bolt isn’t coming out or you’ll be shopping for an Orion. Of course this was a good excuse to upgrade and I do love the sm465/4:1 combo.

Does an Orion bolt right up or is it the same thing where you need the SM465 output shaft tapped for it too?

So here’s a thought, probably a dumb one...since there’s a 9/16” hole drilled in it, what if I welded the $&@! out of a 9/16” bolt with the top cut off into the hole? It would essentially make it a stud that I could put a locking nut on. Is that a crazy idea?

Man this steel is hard! I have been slowly turning the tap and going back and this is all I’ve gotten done. I’ll keep pouring cutting fluid on it and trying not to break it. The last little micro turn I made was pretty sketchy. I think it was about to break. How have other people been able to do this with relative ease? This shaft is hardened the whole way through. It’s not like you get through a layer and then it’s easier like I’ve seen some people post.

 

[archie73]

Does an Orion bolt right up or is it the same thing where you need the SM465 output shaft tapped for it too?

As I understand it, the Orion is designed as a cast iron replica of the LC transfer case for the Banderettes. It’s not cheap, but if you like low gears the 4:1 is awesome. AA has input gears for the 10 spline and I think the fine spline output. Their is a sticky at the top of the 40 Tech page
Sorry I can’t be more help on tapping the output shaft. It’s a bit out of my depth

 

[pbgbottle]

I remember reading to heat up the shaft while tapping get it hot and tap it
I could be wrong but I thought I read that somewhere

 

[SC Forester]

I have heated the $&@! out of it and tried Tap Magic cutting fluid. Tonight my tap broke. I can’t keep throwing money at trying to tap this thing. I’m putting the old 3 speed back in.

I have two complete functional SM465 transmissions for sale and a completely unused plate adapter if y’all know anyone that needs this.

 

[SC Forester]

I have heated the $&@! out of it and tried Tap Magic cutting fluid. Tonight my tap broke. I can’t keep throwing money at trying to tap this thing. I’m putting the old 3 speed back in.

I have two complete functional SM465 transmissions for sale and a completely unused plate adapter if y’all know anyone that needs this.

View attachment 2752040

View attachment 2752041

View attachment 2752042

View attachment 2752043

View attachment 2752044

The broken tap ain’t coming out of there but it’s flush with the end of the shaft. This was a rebuilt SM465 4x4 transmission I bought for this project. I’ll take $400 for the whole transmission and unused plate adapter if anybody is interested.

 

[archie73]

Sorry to hear about the tap failure. I get why you’re going back to the three speed. Have you given any thought to using a ‘40 four speed instead? It’s not as low as the sm465, but the purists speak highly of them.

 

[SC Forester]

Sorry to hear about the tap failure. I get why you’re going back to the three speed. Have you given any thought to using a ‘40 four speed instead? It’s not as low as the sm465, but the purists speak highly of them.

Knowing what I know now I wish I had gone that route. I might in the future if I can source one.

 

[B y r o n]

Taps are hard and if you don't have access to a tap removal tool it is possible to break the tap out of the hole with a punch or small chisel. If nothing else check with a local machine shop and don't give up since you have got this far.

 

[Gotta40]

i've had luck using a torch to get out broken taps. it will heat the tap but not the shaft around it, and you can carefully blow it out of the hole.

 

[shipmag]

i've had luck using a torch to get out broken taps. it will heat the tap but not the shaft around it, and you can carefully blow it out of the hole.

Try welding a smaller diameter bolt maybe a 3/8 but short. Then you have a hex head to tap a little both directions on the wrench until it breaks loose and comes out.

 

[SC Forester]

This transmission just hates me and doesn’t want to go in the Cruiser. I tried using some heat, a chisel, and a punch and then this happened. This stupid hard shaft cracked in two places but still won’t give on the inside! The broken tap is still in there tight while it’s broken around it.

 

[SC Forester]

So...I’m going to put the 3 speed back in it. I may take the SM465 apart and put a pre-tapped shaft in it down the road if I don’t just sell everything. I’ll sell the busted shaft SM465 with a BRAND NEW plate adapter for $250. I paid $250 just for the adapter a few months ago.

 

[SC Forester]

So...I’m going to put the 3 speed back in it. I may take the SM465 apart and put a pre-tapped shaft in it down the road if I don’t just sell everything. I’ll sell the busted shaft SM465 with a BRAND NEW plate adapter for $250. I paid $250 just for the adapter a few months ago.

Will throw in the 3 speed transfer case with all the top shifter linkage for another $100. $350 for it all.

 

[pjohnson]

...I may take the SM465 apart and put a pre-tapped shaft in it...

This is a good plan. Stick with it, you're not that far from the finish line.

Call Georg or put out a wanted ad for an output shaft. Get it cut & tapped, and finish.

 

[shipmag]

This is a good plan. Stick with it, you're not that far from the finish line.

Call Georg or put out a wanted ad for an output shaft. Get it cut & tapped, and finish.

Yep time to call Georg valley hybrids

 

[SC Forester]

I just sourced a 1977 FJ40 4 speed and gonna go that route now. I have a lot of SM465 stuff for sale now if anybody’s interested.

Sorry to hear about the tap failure. I get why you’re going back to the three speed. Have you given any thought to using a ‘40 four speed instead? It’s not as low as the sm465, but the purists speak highly of them.

a

 

[SC Forester]

Yep time to call Georg valley hybrids

I emailed their site and they referred me to some transmission warehouse in Portland. I just sourced a Toyota 4 speed so I’m gonna go a different route now. I have a lot of SM465 stuff for sale now.