2009 4.0 Auto to manual swap.

Welp, after months of debate I finally decided its time to start acquiring parts.

There’s not many swap threads for the 2nd gen auto to manual. So I figured I’d start my own to document my progress.

Yes I know, it’s easier to get a new one, but I like my truck, plus it will be a fun experience.

The truck is a 2009 Doublecab Base 4.0 4x4 Auto

I’m keeping the 4x4 and swapping in the RA60F.

Parts list so far:

RA60F 6speed Trans

6speed Transfercase / (or swap the shaft from 23 spline case to the auto case)

Debating on going with the Clutchmasters hydro bearing kit but not set in stone. (Bought the Kit)

Clutch Pedal assembly

Brake pedal itself (or cut auto pedal)

Clutch master cylinder

Clutch Slave cylinder and accumulator (Deleted both of these by adding the HydroBearing)

Clutch hardline from cms to passenger lower firewall (Did not need this, Clutchmasters kit came almost perfectly to the firewall.

Clutch kit and flywheel

Throwout bearing

2009 MT 4x4 ECM ( you can run the auto one, you’ll have a check engine and a delay on throttle after shifting.)

MT emergency brake handle ( Because the Auto foot E-Brake is where the clutch pedal assembly sits)

4x4 MT crew cab driveshaft or 1” spacer

Supposedly auto and manual 4x4 crossmember / trans mount are the same
(If your truck is 4x4 the mount and crossmember is the same)

Hole in trans tunnel ( there isn’t a plate like the old years)

And the lower dash trim / shift boot.


So, As I gain parts (And time to work on this) I’ll be installing all the smaller interior bits and checking if Toyota has left the unused MT connectors in the harness as usual.
I wont know until I do some more fishing around once the foot E-brake is out. I’ll update as I go.

 

Pedal Ebrake is removed, Auto cable is removed.
I installed the manual cable, but the rear mounting bracket still needs holes drilled to support it.
The front of the handle bolts with 2 10mm to the metal bracket under the coin tray.

Under the pedal ebrake there is a mount on the firewall with 2 studs that used to hold on the pedal brake. That needs to be cut off to make sure the clutch assembly sits down flush.

Will update after I cut the plate off. I will also update with some pics.

 

This is insane, but also fascinating. Props to you man

 

I haven’t seen it done on a 2009 yet, so I’m taking the plunge.

 

Hope it goes well, definitely watching this thread

 

My clutch pedal has arrived and I mocked up the assembly. There’s a bracket with two bolts on it that is spot welded to the firewall where the clutch lines go. I drilled out the spot welds, but you could just cut the bracket out if you wanted to take your time.

there’s an indentation on the firewall that exactly matches the shape of the clutch mounting bracket. I made a cardboard template and started drilling. Hoping for the best I placed the bracket up and were golden.

*Note* when your drilling, watch out for the booster. Some of the holes are a bit behind it on the firewall.

I’m waiting to install the clutch assembly back in until my manual brake pedal arrives. Shipper messed up my address so it’s a waiting game at the moment .

Regardless though, I’m still trying to decide if I should go with a hydro bearing kit or not. Ive heard its hit or miss.

The wiring for the cruise control switch and the Clutch start switch I cannot find on my harness, so, Using my FSM i found what I believe I need to tie them in.

 

As of tonight, The brake pedal assembly should finally be here on Wednesday.

Clutch kit and flywheel should be here on the 6th or so.

Hydro Bearing should be ordered in the next few days.

Going to go to the wrecking yard to possibly snag a MT Transfercase and a driveshaft. Still haven’t located a 2009 V6 4x4 double cab MT ECM yet.

 

Good luck on this project! The world needs more manual trans vehicles!

 

I believe it. Its just more fun. I would have bought a manual trans if there was any for sale when I needed a truck. But since there’s attachment to the truck now, it’s now a quarantine project haha.

 

Good luck with the project!

 

Brake pedal arrived a day early. Left the auto mount on the firewall. There’s the 2 12mm bolts at the bottom holding the assembly on. There’s the spring at the top near firewall and a pin with a clip that holds rod from booster / master cylinder. Remove those and the whole assembly comes down. Replace in reverse with the manual version.

Lined up the clutch pedal assembly and installed the two bolts through the firewall. All snuggled up and waiting for more parts.

 

Acquired a MT Transfercase today with a V6 4x4 MT Crew cab rear driveshaft. Pick them up tomorrow. Just need to order the HydroBearing and it’s install time.

 

Picked up the V6 MT Transfercase today, and a V6 4x4 crewcab MT driveshaft as well. Clutch kit and flywheel also showed up today. I’m about ready for to drop the auto.

Also just put in my order for my Clutchmasters HydroBearing.

 

Subbed! Finally, thank you so much for making this thread, please keep posting in more detail! I can’t find much info for the 2nd gen auto to manual swaps, just a bunch of “hurr durr itz cheaper to sell ur truk n buy anuther”

I know I want to do a 4x4 conversion and might as well get a manual trans if I have to buy a new trans anyway. Best of luck to you!!

 

So do you currently have a prerunner 2wd?. * just read your bio. For you, You might have to get a custom driveshaft. Because the 4x4 trans mount and crossmember is a bit farther back then the prerunner. Be prepared though. Its a bit of a challenge and a decent $ amount. I’m somewhere between 1.5 and 2k in parts already. And i am a stock 4x4

 

Yea I’ve read you definitely need a custom crossmember for the prerunners, I think rock solid toys sells them. I’m assuming the manual transmission lines up with the auto transmission crossmember. That’s a lot but I’m expecting around 4K total for me. How much further do you have to go? Looks like you have most of the parts

 

The manual transmission does line up and use the auto 4x4 mount and crossmember. I just have to buy an ECM to have it fully done. Well and wire the clutch start switch (2wires) The cruise control switch (Also 2 wires) and tie those into the park neutral connector under the auto shifter. And unpin the auto connector for the transmission that held the reverse trigger wire and reverse ground. ( I’ll put those two wires into the MT 2 pin connector and plug them into the MT reverse switch on the side of the trans. But I can drive it with the auto ECM and a bunch of check engine lights. To be fair, I only need the clutch start switch two wires to fully start and drive it.

 

New Flywheel and pressure plate assembly. Somehow they forgot to ship the clutch disk. So that’s a setback.

 

If you haven't checked out the HPTuners thread (https://www.tacomaworld.com/threads/hp-tuners-for-2005-2015.600793/), I've personally tested/ran a Auto ECU in my '15 Manual truck without any check engine lights/throttle hesitation/etc. Granted, it does require some "tuning" with HPTuners to get that done, but I wanted to throw it out there, that I can in essense convert your Auto ECU to function with a Manual truck without any lights/quirky behavior if that's something you'd be interested in.

I could also supply you with a Manual trans ECU with the VIN reprogramming to match your vehicle (for inspection purposes).

If I can be of assistance, let me know.

 

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