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M41 installation problem 120-130

posted by  nglasson221 on  Fri Mar 2 20:15 CST 2007
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I am in the process of fitting an M41 gearbox to my 1963 Amazon wagon. I salvaged the M41 from a 1971 142E and have just fitted it up into the wagon. I kept the longer speedo cable but had to machine up a bush to adapt from the M12 thread on the Amazon speedo to the M16 that is used on the 142E.

My current difficulty is how to handle the difference in size of the output flanges from the respective gearboxes. The M40 Amazon output flange is much smaller and uses smaller diameter bolts to bolt to the drive shaft. See picture below.

The output flanges are clearly not interchangeable. I can't swap the drive shaft either - totally different. I thought of cutting the front off the 142E drive shaft and machining it down to weld into the smaller diameter tube of the Amazon front shaft. The down side of this is that the larger universal joint from the 142E will almost certainly foul of the tunnel. The large universal is also about 1/8" too large to fit through the tunnel from the rear - I'd need to have the drive shaft in place before fitting the gearbox!

I have a few options to think about:

1. Drill 4 new holes in the large output flange so that the smaller drive shaft flange can be bolted on. I would need to machine up a spacer ring to make up for the 1/8" difference in the size of the locating spigot. I would also need to either tap the holes or grind away the head of the bolts so that they will fit against the body of the output flange. The bolt holes will be very close to the recess that the drive shaft spigot fitted into.

2. Make up a short adapter piece to go between the larger flange and the smaller flange. It would be drilled and tapped for bolts from each side.

3. Try and track down a different output flange for the overdrive that is compatible with my Amazon drive shaft flange.

I really need to pick the right answer before getting the drive shaft cut down. I don't want to re-work it twice.

Has anyone else encountered this problem? What is the best fix? I'm favouring option 1. for now but I'd welcome any other suggestions.





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New M41 installation problem [120-130]
posted by  nglasson221  on Fri Mar 2 20:15 CST 2007 >


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