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Adapting the

GM Muncie SM465

to the

Jeep Models 207, 231, 242, 249, 241J & 241OR Transfer Cases

Adapter kit for SM465 to Jeep transfer cases

Kit 461, adapting the SM465 transmissions to the Jeep NP 207, 231, 241, 241OR, 242 and 249 transfer cases with 23 spline input


Kit Contents

  • Adapter housing
  • Transmission mainshaft, 23 spline output
  • Seal extension
  • Seal
  • Transmission to adapter gasket
  • Adapter to transfer case gasket
  • Steel mounting base foot
  • Fasteners
  • Instructions

Our SM465 to the Jeep New Process (or New Venture) transfer case conversion makes for an impressively strong and capable assembly both on-road and off-road, and it remains one of our most popular manual transmission to transfer case combinations.

The Novak SM465 to Jeep NP / NVG transfer case adapter is compact at only 3.2" long for a combined transmission and adapter length of 15.2". The adapter itself is cast and machined of 356-T6 aluminum heat treated alloy, featuring thick flanges, a heavy cross-section, and strength-adding gussets. It is drilled for over 20 degrees of transfer case clocking locations, though the provided factory angle will suffice for most New Process transfer cases.

This transfer case adapter's design features a modular mounting and support system and mounting base, ready to accept our industry standard urethane isolator mount, available in Related Products, below.

The new Novak manufactured 23 spline output shaft is machined from premium alloy steel and hardened for maximum strength and longevity ready to be installed in your Borg-Warner transmission and then spline directly into your 23 spline transfer case - a 21 spline version is not available. Details below.

Applications & Compatibility

sm465_with_463_adapter_rear_quarter_viewTransmissions

Any version of the SM465, including 2wd, 4wd early, and 4wd late styles are compatible with this adapter assembly. There are no advantages between the 2wd vs. 4wd versions of this transmission.

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Mainshaft replacement is largely straightforward. Good work is within easy reach of the careful home mechanic and instructions are included. We recommend at least our basic gasket & seal kit and the SM465 the mainshaft bushing set. Better yet, this is a good time for a more thorough master rebuild and update of the transmission. See Related Products, below.

Many customers ask us for our complete Novak remanufactured and upgraded transmission packages. It's a professionally built transmission, dyno-tested, delivered and ready to bolt in.

Compatible NP & NVG Transfer Cases

The adapter kit is designed for compatibility with 23 spline Jeep NP207, NP231, NP242, NP249, NP241 & NP241OR "RockTrac" transfer cases. Below is a summary of spline counts and lengths usually encountered.

Transfer case seal spacer
New Process input gears come in varying spline counts and lengths. Whichever you have, we've got you covered. A seal spacer sleeve is included and pre-installed in your Novak adapter in the event your transfer case has a short input gear.
  • NP 231 - The NP231 may have 21 or 23 splines and a long or short style input gear
  • NP 242 - The Jeep version NP242 may have 21 splines for the 1987-1990 versions. When connected to the 4.0L HO engine (1991- ) the 242 will have 23 splines as will the Dodge and later V8 Grand Cherokee, AMG versions are 32 splines long
  • 249 - The NP249 always has 23 splines, but may have a long or short style input gear
  • 241OR - The RockTrac will always have a 23 spline, short style input gear. Its gear is unique and not interchangeable with any of the other versions due to the lower 4:1 ratio
  • NP207 - The NP207 may have 21 or 23 splines. Many versions feature extra-long input gears whose stick-out lengths (as measured from the front edge of the input gear to the transfer case front mounting face) longer than 2.2". These will require shortening with a cut-off saw and/or lathe and finished with edge breaking chamfers. New 23 spline NP207 input gears are available in Related Products below.

A more detailed discussion of New Process input gears is found here.

No 21 Spline Version?

The 21 spline shaft is substantially weaker than the 23 spline version. 21 spline versions were only used in the 4 cylinder applications and some very early automatic 6-cylinder versions. Novak does not make a 21 spline version of this adapter kit because of this weakness, vs. the exceptional torque created by the compound low gear of this transmission.

Our recommendation is to change the transfer case input gear to a 23 spline version. See Related Products, below.

Compatible Jeeps

Many of these conversions are for the YJ Jeeps, in which the SM465 is a terrific match. Even earlier Jeeps that are being retrofitted with the NP231 or similar later transfer cases accept the SM420 well. However, TJ and XJ Jeeps with their significant dash consoles may pose an interference problem with the SM465's shifter and top tower. The 465 is a shorter and taller transmission than factory options in these later Jeeps. Individuals should be aware of this caveat.

Compatible Engines

Any engine that can be made to work with the SM465 will work with this conversion. They include:

Related Products


Urethane Rear Mount for Crossmember

Urethane Rear Mount, #RMU

This rear mount bolts direct to your Novak adapter, and can be used with a variety of crossmember styles.

Pilot Bushings

your transmission will require a pilot bushing to your engine of choice. See the various options, here.

SM465 Gaskets Kit

Gaskets set, SM465 transmission, #WT304-55

This is the gasket kit to seal up your SM465. This is included with our master rebuild kit, adjacent.

SM465 mainshaft journal bushing kit

Kit B465, bushings, SM465 mainshaft journals, 1st, 2nd & 3rd gear, #B465

If purchasing the mainshaft version of the Novak adapter kit, these bushings are required. Note that these also come in our master rebuild kit (adjacent). If purchased at the same time as the adapter kit, we will press one of the bushings on the mainshaft for you - the other two must be installed with your gears due to sequencing.

SM465 transmission parts

Kit 465MR-1, master rebuild, SM465 transmissions, 1968-1987 versions

This is Novak's curated master rebuild kit for the SM465. There is not a more complete kit on the market. See it here, along with other SM465 rebuild, repair and upgrade components.

SM465 transmission parts

Kit 465MR-2, master rebuild, SM465 transmission, 1988-1991 with wide front bearing

This is Novak's curated master rebuild kit for the late SM465. There is not a more complete kit on the market. See it here, along with other SM465 rebuild, repair and upgrade components.

Kit, update, 3rd gear and slider, SM465 transmission. TorqueLock / Anti-jump-out design, #WT304-11AX

The SM465 is pretty close to perfect in its design, but this update to 3rd gear and its slider are considered to be essential. The tapered clutch design prevents 3rd gear from kicking out under torque. This and other components can be seen here.

Shifter Retention Kit, SM420, SM465, T176, NP435

Kit, shifter retention, SM420, SM465, NP435, T176 transmissions, #SLR-176K

This shifter retention kit and mini-boot will lock in your shifter stick and give it a better barrier than factory from dust and water ingress.

Shifter stick for SM465

stick, shifter cane, SM420 & SM465 transmissions, upgraded finger, 18" tall version, WT304-28-18

Many of our customers request this stick to replace the missing, worn or mishapen factory shifter cane. This version is for cast iron top covers and is 18" tall; more appropriate for many Jeep applications. It features the solid finger design, instead of the wonky, two-piece factory finger design.

Shifter stick for SM465

stick, shifter cane, SM420 & SM465 transmissions, upgraded finger, 24" tall version, #WT304-28-24

Many of our customers request this stick to replace the missing, worn or mishapen factory shifter cane. This version is for cast iron top covers and is 24" tall; more appropriate for full-size Jeeps where the bulkhead and dash are deeper and will require more bends. It features the solid finger design, instead of the wonky, two-piece factory finger design.

Shifter stick for SM465

Stick, shifter cane, SM465 transmission with aluminum top cover, #WT304-28A-18

Many of our customers request this stick to replace the missing, worn or mishapen factory shifter cane. This version is for the aluminum top cover and is 18" tall; more appropriate for many Jeep CJ or Wrangler applications. It features the solid finger design, instead of the wonky, two-piece factory finger design.

Shifter stick for SM465

Stick, shifter cane, SM465 transmission with aluminum top cover, #WT304-28A-24

Many of our customers request this stick to replace the missing, worn or mishapen factory shifter cane. This version is for the aluminum top cover and is 24" tall; more appropriate for full-size Jeeps where the bulkhead and dash are deeper and will require more bends. It features the solid finger design, instead of the wonky, two-piece factory finger design.

SM465 Countershaft Billet Front Cover

Kit, cover, front, countershaft, SM465 transmission, #465CSC

This billet aluminum front bearing cap for your SM465 countershaft is far more rigid than the stamped steel, leakage-prone factory unit. It comes with countersunk fasteners.

Billet PTO Cover

Kit PTO-K, PTO cover, six bolt style, billet

This is the rigid PTO cover that every Novak-built transmission gets, and we recommend them to our customers. They seal better and stay that way for far longer than the stamped steel versions from the factory. Stainless button-head fasteners are included.

1976-1986 Jeep floor tunnel cover

1976-1995 Jeep CJ & YJ Floor Tunnel Cover

Start with a clean slate tunnel cover for your 1976-1995 Jeep CJ / YJ floor. Cut your shifter holes and install boots onto it as required. Material is aluminum. Can be painted. More info here.

Shifter Kits for New Process Transfer Cases

As this combination will frequently be paired with Jeep New Process chain drive transfer cases (NP231, NP242), this shifter kit will make the conversion go not just smoother, but will improve your shifting action and reliability significantly over factory. Read about them here.

NP231 transfer case parts

NP231 rebuild, repair and upgrade parts

Some transfer cases are due for a re-seal or even full rebuild. We carry the world's most full-featured kits and components, here.

NP242 transfer case parts

NP242 rebuild, repair and upgrade parts

Some transfer cases are due for a re-seal or even full rebuild. We carry the world's most full-featured kits and components, here.

NP242 transfer case parts

NP242 rebuild, repair and upgrade parts

Some transfer cases are due for a re-seal or even full rebuild. We carry the world's most full-featured kits and components, here.

Transfer Case Input Gear, 23 Spline

Gear, input, New Process 23x & 24x transfer cases, 23 spline, long input, wide bearing, early gear cut, 1.5” pocket bearing, #23LWES

If you have a 21 spline input gear in your early (1988-1993) New Process 231, 242 transfer cases, swap it for this gear. Read more about these gears, here.

Transfer Case Input Gear, 23 Spline

Gear, input, New Process 23x & 24x transfer cases, 23 spline, long input, narrow bearing, late gear cut, 1.5” pocket bearing, #23LNLS

If you have a 21 spline input gear in your late (1994-2006) New Process 231, 242 transfer cases, swap it for this gear. Read more about these gears, here.

NP207 Input Gear 23 Spline

Gear, input, New Process 207 transfer case, 23 spline, long input, #716096

This is a new 23 spline input gear for your NP207 transfer case. As many of these were 21 spline models from the factory, this permits the upgrade to the stronger 23 spline design for compatibility with the Novak adapter kit.

Turn-Key SM465

Turn-Key SM465 Transmission

Let us put a meticulously remanufactured and updated SM465 on your doorstep, configured exactly how you want it for your project, with the appropriate adapter (or factory tailhousing), bellhousing preparation, etc. Read more.


Installation Requirements

Tools

The transmission shaft installation takes more specialized tools, heavy snap ring pliers, a press to remove and replace bearings, etc. Normal mechanics tools are required for the balance of the installation.

Clocking Information & Driveshaft Clearance

Our adapter is drilled for multiple clocking locations and driver’s side drop transfer cases usually clear nicely in most all applications.

Engines & Engine Mounting

GM Engine Mounts for Jeeps

Factory engine placement on YJ Jeeps is great for the SM465 transmission, whether using an I4 or an I6 engine. If installing an AMC or GM V8, your engine mounts should permit about a 1-1/4" offset towards the driver's side. Novak's engine mounts, feature vibration dampening, superior strength.

Driveshafts

Driveshaft length changes are often required. Most conversions to these transmissions will require that the rear driveshaft be modified to be shorter and front driveshaft longer.

Some installers, concerned about the expense of new or modified driveshafts, attempt to let the existing driveshafts dictate engine, transmission and transfer case location, often to the detriment of the project. Our recommendation is to prioritize the correct position of drivetrain components over saving a few dollars which is usually regretted in the long run with compromised positioning.

Jeeps that require extensive travel or specialty-built driveshafts have this option available through several fabricators across the nation. These are normally specified after placement of the new transmission and measured at vehicle ride height. As the rear driveline gets shorter, it is often advantageous to us a Double Cardan or “CV style” rear shaft with the correct geometry at the axle to minimize vibrations and possible binding.

Axles

Use of factory axles is completely acceptable with this conversion. Axle upgrades are not necessary, but they may be chosen for reasons external to this transmission upgrade.

Also See