Willys Jeep SM465 Transmission Upgrade - 4-Wheel & Off-Road Magazine

Willys Jeep SM465 Transmission Upgrade - Granny’s Tranny Fred Williams Brand Manager, Petersen’s 4Wheel & Off Road

Old Willys Jeeps are as popular as ever these days, and old Jeep owners all have different recipes to build theirs. Lots of off-roaders are heading toward automatic transmissions, but there is something about a manual transmission that just feels right for an old Jeep, so we’re going to showcase a simple tough gearbox arrangement that is short in length but offers multiple gear options.

Grannys Tranny Sm465 Transmission Upgrade Sm465 Transmission And Transfer Case Photo 47758121
The Spicer 18 helped beat the WWII enemies from inside every Jeep

A classic recipe for old Jeeps has always been the super-granny-geared SM420 transmission from a GM truck with the original Spicer 18 transfer case. This is a great setup for its low gearing and short overall length, but we have found something even shorter. The SM465 is the replacement for the SM420 in GM trucks and can be adapted to the offset Spicer 18 to give you an even shorter overall gear train. Plus, by adding new over and under gears to the 18 you can still have a wide variety of gearing options. We would still like to see a short five- or six-speed transmission in a little Willys CJ someday, but this recipe offers a strong simple gearing solution that makes sense in an old Jeep.

Grannys Tranny Sm465 Transmission Upgrade Sm420 Transmission And Spicer Transfer Case Photo 53081943 This is the old standby when it comes to Willys Jeep transmission and transfer case combos: the GM SM420 and the Spicer 18 transfer case. This allows easy adaptation to a GM engine like a V-6 or V-8 since the transmission came behind a GM engine. The SM420 has an immense low range of 7:1 and was last offered in a GM vehicle in 1967. PhotosView Slideshow The SM465 is heavier by 40 pounds, only has a low gear of 6.55:1, and is 11⁄2 inches longer than the SM420. However, it was available up to 1991, and where the SM420 uses a 4-inch adapter Advance Adapters offers a new output shaft and a 7⁄8-inch adapter so the overall package ends up 15⁄8 inches shorter. The front output of the transfer case has more clearance for a larger front driveshaft with the SM465. You will have to decide if the gearing or the length works best for your project. We opted to go with a rebuilt SM465 from Advance Adapters and had the new output shaft installed at the time of the rebuild. When rebuilt, the common problem of high-mileage SM465s popping out of Third gear was fixed with a Third gear upgrade kit with a torque-locking slider and gear kit. Because the transmission is rebuilt with the new output shaft, any version (long or short output, 2WD or 4WD) can be used. The Spicer 18 transfer case has a long history in the Jeep world since it pretty much arrived on the scene in 1940, helped beat the WWII enemies from inside every Jeep, and then stuck around until the early ’70s. The iron case has both the front and rear outputs on the passenger side, a benefit because they keep the differentials in line for dodging trail obstacles, plus it helps lower both the front and rear output for better driveshaft angles. The Spicer 18 has a variety of low-range gearing options, but the most common is a 2.43 or 2.46:1. This isn’t bad, but we opted to downshift even further with the Teraflex 3.15:1 gearset. This, combined with the 6.55 First of the SM465, and our planned axle ratio of 5.38 gives us a crawl ratio of 111:1, perfect even with our planned four-cylinder engine (more on the engine in a later issue). Before we stuffed the TeraFlex gears in our 18, we tracked down a Spicer 20 from a ’62-’79 Jeep. The Spicer 20 has a stronger case than the earlier Spicer 18, and though it is a centered rear output case it is possible to swap in all the 18 internals for an offset rear output. The Dana 20 was available in Jeep, International, Chevy and Ford 4x4s. We took our newer Spicer 20 and older Spicer 18 to Jason Bunch at Tri-County Gear to have a Super 18 built with the TeraFlex gearset. Bunch started by disassembling and cleaning the 20 case that will house the 18 internals. The Spicer 20 case has a large, 4-inch locating bore and 1 1⁄4-inch intermediate idler shaft; some early 18s had a 3⁄4- or 1 1⁄8-inch shaft. The low gearset requires the 1 1⁄4-inch shaft, and our old case only used a 1 1⁄8-inch shaft. To use the TeraFlex gears you’ll either need to build a 20 case like ours or use a ’55 or newer Spicer 18. A small bit of grinding has to be done to fit the larger gears. Some grinding is required along the opening of the case; additional clearance is needed along the inside of the case. Care in cleaning old gaskets from the case and sealing the new gaskets is the only guarantee against leaking, and old Jeep gear boxes are notorious for leaks. Bunch uses new gaskets and gasket sealer after plenty of scraping and sanding on the old seal surfaces. Neither the SM420 nor the SM465 has an overdrive gear. For this reason we optioned the Advance Adapters Saturn overdrive to help drop the rpm for highway cruising. Because the transfer case has both a front and rear passenger offset output, the power from the engine must make a 90-degree turn on its way out to the driveshafts. The Saturn overdrive mounts on the back of the transfer case so the power runs through it in either two- or four-wheel drive, and high or low range. The Saturn overdrive does use a special gear in conjunction with the TeraFlex low gears. This bull gear is smaller than the standard bull gear to fit the larger gearset, but this results in a transfer case with a 3.15 low range, a 1 to 1 hi range, and the 0.75:1 overdrive ratio. This, combined with the SM465, should give our little Jeep plenty of gearing options for all terrains. High Angle Driveline has a new offering of 10-spline driveshaft flanges that are great for Spicer 18 and 20 transfer cases. We ordered a set that will adapt to the strong but small Toyota CV joints for optimal driveshaft angularity options. The slim-bodied SM465 also allows larger front driveshaft options, and the Advance Adapters adapter offers three clocking locations for the Spicer 18 depending on which shifter setup your transfer case has.