SafetyDang DC Build/4wd Swap/Manual Trans Swap Thread

Trip Reports:
Alabama Hills, CA


SWAP INFORMATION
All Research info is at TTORA Truck:
2002
Toyota Tacoma
Double Cab
V6 4 speed Auto
Prerunner


Current Parts:
5 speed Manual Transmission - $250 Birthday Gift
J-Shifting T-Case - $75
Front Drive Shaft - $50 Shipped
Rear Front Portion Drive Shaft - $75 Shipped
T-Case VSS - $75 Shipped
J-Shifter Lever -$39 Shipped
J-Shifter Knob - $10 Shipped
5 Speed Shift Knob - $25 Shipped
Clutch Pedal Assembly - $25 Shipped
Front Diff 4.30 - $264 Shipped
Non Add Diff Output Tube - $114.50 Shipped
Master Cylinder - $67.78 Shipped
Slave Cylinder - $37.78 Shipped
Marlin Twin Stick - $199 (Plus Shipping 10.51) Bought With Trans Mount
Marlin HD Transmission Mount 85.00 (Plus Tax 25.49)
2002 Toyota Tacoma ECU 89666-04010 - $125 Shipped
URD 5vz Short Shifter On Sale - $106.41 Shipped
Manual Hubs Spindles - Package Deal $500
Manual Hubs - Package Deal $500
Manual Cvs - Package Deal $500
4.10 Front Diff - Package Deal $500
Shift Boot And Plate - $39 Shipped
2004 MT V6 Flywheel - $300
Diff Drop Bolts - $31 Shipped
Clutch Hydro Lines and Brackets and Nuts/Bolts.
31481‑04030
90931‑01112
31482‑04040
31484‑35240
90461‑12413
90468‑08046
91611‑F0812
$63.32 Shipped

Current Total Cost So Far 2592.79

After Selling some of the things I don't need $2347.88



I'll Update as I go.

Helpful Links:
Auto to Manual Swap Junglecode Write Up

Other Members Conversion Threads Auto DC to 4x4 - Auto DC to Manual 4x4 (5 speed Manual Swap) Auto DC to 4x4 (Output Shaft Swap) Auto Ext to 4x4 (Using Inchworm)
Interex Auto Ext to 4x4 (Output Shaft Swap)
iceman601 Auto 4-runner to 4x4 (Using Tacoma Trans/T-case)


FAQ


What do I need to swap to a 5 speed transmission?
R150 or R150F (4x4), Clutch, Clutch Cover, Flywheel, Transmission or T-case mount, Slave Cyl, Master Cyl, Clutch Lines, Shift Boot, Shift Cover and a few other little bolts and nuts.Source


Would a 4x4 Single Cab front portion of the rear drive shaft work for my Double Cab or Extra Cab? No Single Cabs drive shaft is shorter then a Double Cab or Extra Cab. Can I use parts from a 4-Runner? For a Tacoma you can use 4-runner parts from a 3rd Gen 1996–2002. Source

If I do a Auto to Manual swap will I throw a CEL? Yes unless you swap out the ECU for a 5 Speed 4x4 Manual. Can I reuse my Pre-runner Transmission for the swap? You have 2 options you can choose from. One is to swap out the 2wd output shaft for a 4x4 output shaft. Two run the Inchworm Prerunner Adapter Plate with a Gear Driven T-case or a Lefty Adapter with a Lefty T-Case. (NO Stock T-Case w/ Adapter)
Sources: Output Swap Prerunner Adapter Plate

Can I use my Prerunner Vehicle Speed Sensor? No, They are different. Source

Can I use my Prerunner Rear Drive shaft? Yes but the front portion after the Center Carrier Bearing must be shortened 12" Inches. If I use Manual Hubs will I keep my ABS? Only way to keep ABS on manual hubs is to press the Manual hubs into your ABS spindles. Will a T-Case from a Manual transmission bolt to an Automatic transmission? According to "input shafts are different lengths between auto and manual" *Update According to js_iron "They are the exact same output shaft length and they both will bolt right up to the A340F" Can I use a 2.7 T-Case for my 3.4 Transmission.

Can I use ADD CV's with my Manual Hubs? No, the ends are different. How do I wire up my clutch cancel button? "If you want the clutch start safety feature with over ride switch, best to cut it out of the wrecked truck harness and piggy back onto your DC harness." - mattm94 First Collect Some Parts..

T-case

Transmission

Front Drive Shaft

Rear Drive Shaft

T-Case, Transmission, Rear Drive Shaft, Front Drive Shaft

Clutch Pedal From a 98

J-Shift lever

Some Shift Knobs



--------------------------------------------------------

Clutch Location
My Brothers 5 Speed Extra Cab (Mind The Grease)

My Double Cab


Cross Members Are in the same Locations for Double Cabs and Extra Cabs

Auto Double Cab PreRunner


5-Speed 4x4



Install Manual Hubs and Diff....





Broken.... =[



Bam!



Messing with the springs on the Hubs..



Done




Do Needed Mods...















Sealant part number.


Cleaning it up.














Shift Knobs bugging me... They never lined up right..


Off to modding them... little spacers...


Bam! Lined up!



Waiting for Amsoil Transmission fluid and my LCE 38lb Flywheel has not come yet...

Bam...





Got bored.. Eye balled it.. Luckily I got it dead on!


Cleaned the T-Case w/ Twin Sticks


Test fit, make sure I got the right T-case..


Installing URD Short Shifter





Cleaning..





Deciding where to bend or cut the Twin Sticks


Clearance Problems in Reveres and 2nd and 3rd Gears.. In low.. or 2wd

 

Remove Drive shaft






Remove Transmission Drain Plug



Drain...



2wd tranny still there...


Remove Clips... Clips.. And More CLips!







Making a mess...



Flex plate



Ghetto Transmission Jack..





Cut my exhaust because mine no longer had flanges to unbolt..



Unbolt....





SuperChiem may use this for the RV... Needed a Speed Sensor.

 

Removing Transmission Lines


Passenger Side







Driver Side





Removing torque converter





Got to the flex plate





OEM Clutch lines...

Master Down... I think I may have to move my Master Cyl up a little bit.. But we will see...



Moving Brake Booster Wire







Connecting the Master To the Flex Hose


Flex Hose to Slave Line



End of the Slave Line came with this plug... Hm....



Which gave me an Idea...



Condom!

 

:saw:


:saw:





Found a broken stud in the bell housing..



Removed the bell housing.



Tried Vice Pliers


Drill...



Tap... didn't come out... PO had it like this as well, but I wanted to fix it...



Also Cleaned the Bell Housing

Before:


After:


Installed the LCE 38lb Flywheel.. torqued to 63 lbs



Installing the clutch pad.. Fat side is the flywheel side,



The SST should come in and out easily...






Then it rained... and I had class



What Fluid to use...

 

Spot Saver

 

Maybe 1 more spot saver..

 

I just swapped my 2wd.. this looks more extensive haha

 

Damn!

 

Sweet.

 

sub'd

 

Should finish up in the next week or so if time works with me.

 

I love the grease on the spring. I did the same thing on both the 95.5 and 98 I had previously to shut them up. Kudos for taking this on. I know a lot of people are scared of this kind of stuff and advise others to just buy another truck. If my auto tranny in my 96 starts to give me issues I'll be swapping a 5 speed into it. But mine's already 4WD so I won't have quite an extensive parts list.

 

Now this is how you make a walkthrough. While I will never have to do this swap, thank you for taking the time to detail it.

And I agree with mbassman. Ditch that torsion spring in the clutch pedal and go with a brake return spring.

I doubt your DC has the welded tab behind the dash to hook it on to, but it seems like you might be somewhat mechanically inclined to figure something out

 

I'm so jelly! I want a 5 speed.

 

I was planning to do the spring thing never got around to it. Doing more on Thursday...

 

sweet project man!

only way id want a tacoma is with a 5 speed. Id do this..or try..haha

 

You'd be surprise what double cabs have. They have the mounts for the clutch hydro lines and some mounting hole for the clutch peddle. I'm sure its down there.

 

Updated

 

I also found that my 2wd I4 cab had a lot of stuff for the 4wd V6 cab..some..was missing a lot too..

 

Wouldn't make sense for them to change the cab.. Especially since Toyotas all about flow in the factory. Having 2-3+ lines for different cab configurations. IE ( Manual/Auto ) would slow them down especially if its just a different mounting bracket. This is the Toyota Production System (TPS) at work.. "Producing high-quality vehicles as efficiently as possible".. or so they say.