2003 Auto to Manual swap

Wanted to start a thread to document my auto to manual transmission swap on my 2003 XCab. I was inspired by @SafetyDang and his older posts over on TTORA. I started the journey today by picking up the following parts from a fellow TW member who was parting out a 2002:
- R150F Transmission and transfer case
- both shifters
- crossmember
- front and rear driveshafts
- Marlin crawler flywheel
- clutch/brake pedals and associated pigtails
- master cylinder
- ECM (though we’re not certain this will work)
- console, shift boots, misc. stuff

 

I am going to order a new slave cylinder, clutch disc + diaphragm, throw out/release bearing as well as the pilot bushing. The fellow I bought the stuff from is an ASE tech for a local VW/Toyota dealer, so he is going to get me all the OEM stuff at his cost. Super nice guy. He was original owner of the 2002 and it just rotted out from under him. Damn NJ winters.

 

Of course my I broke one of the small bolts for the slave cylinder as I started to clean it up today. Grrr…

 

Watching.

Want to do this for my 04

 

I salute you. FYI I highly recommend the URD short shift kit while you’re at it. I just installed one one mine. Also the heavy flywheel if you ain’t got one already.

And the Marlin crawler shifter bushings

 

I have the heavier Marlin flywheel and the PO did the shifter bushings already. I think it has the stock shifter though. I’ll post a close up tomorrow.

 

Still doing some parts gathering and definitely want to get a transmission jack. I have a two-post lift in my home shop, so I was considering something taller than the HF one, but am interested in any recommendations folks have.

Also, how would you recommend I clean up the driveshafts? Would you just use a wire wheel/brush to knock off the heavy rust and paint them with Rust-o-Leum paint?

 

That’s what I did with mine. Might consider the u joints while you’re at it. There’s a dedicated tool on Amazon that makes it a relative breeze. Also I used the HF jack on my transmission and it did the job. Not the best, but it worked.

 

Is it assumed that grinding off the rust will improve the balance of the drive shaft? I guess I figured you didn't really want to touch it, even if it's rusted up. But i guess maybe it makes more sense to tackle it?

 

Jealous of this! Wanted to manual swap my double cab, but the parts list required was daunting. Maybe I will do it when this automatic fails me.

 

Good Luck OP

If it does not matter if your drive shafts are balanced clean the best you can. If you will be driving on the street I would take them to a drive shaft shop to be done correct . Maybe you have a Lathe or friends to do the work yourself . I learned this lesson the expensive way .

I just need to say every auto to manual swap all included a 4x4 conversion as well.

I always buy a complete donor vehicle that can be driven to make sure every thing works when I start.

It never fails it is the little things that are time consuming .

 

Lce has thr heavy weight flywheel. Marlin crawlers is just a luk flywheel. Not to say it isn't bad.
Be sure to do the rear main seal since you are there also, and check the back of your engine for any coolant leaking by the lower intake manifold while you have a good view.

Another easy and cheap peice of preventative maitence would be the output seals on the transfercase. For the front and rear driveshafts.

That short throw mentioned is one of my top 5 mods I've ever done to my truck. If Marlin crawler has theirs In stock you can go that route and it includes the bushings, but the urd kit has proven just as nice to drive.

Good luck op

 

Not sure which transmission OP is using or which engine he has but Marlin doesn’t make a short shifter for the one that goes in a 3RZ and has no plans to make one. I asked em.

 

Oh good point. Can the r150f mate up to the 3rz? I have a 5vzfe so, if that's what he has then he's golden haha. Either way it's more expensive than the urd kit which is still awesome (and what I have)

 

5VZFE engine here. R150F trans. My truck is already 4x4, so I am not doing that conversion, just auto to manual.

I will get a rear main seal as suggested. How easy is that to change?

 

Nice! 5vzfe ftw
Super easy if you have the flywheel off and trans out. You will kick yourself if it leaks and you didn't do it

Rear main seal pn#- 90311-A0027

 

Thanks erice! I’ll order it tomorrow!

 

Feel free to contact me on IG if you have any questions. I'm not usually on TW anymore.

 

Thanks SafetyDang!

Got more parts yesterday. Clutch, pressure plate, slave cylinder, hard lines, throw out bearing, neutral safety switch, flywheel bolts. My flywheel is being cut today.


I’m going to work on getting the pedals and the master cylinder installed this weekend. I’m still waiting on a part from Marlin’s and I still haven’t decided on a trans jack. Im looking at the hi-lift ones as I have a 2-post service lift. It’s just that they are either Harbor Freight cheap ($200) or Sunex expensive ($800).

 

I also picked up these headers, but that’s for a later project