'06 Prerunner conversion to 4x4

Well, I am done.

I had a few hiccups along the way. First was cutting the output shaft of the transmission down. I knew I would have to do it but I didn't want to cut it too short. So I would measure then give myself room for error, mount the t-case, then cut again. Did it about three times. That transfer case gets heavy.

The reason for the adapter is because the output shaft is not splined all the way back to the transmission and the shaft is long. If they made the adapter thicker then you would run out of room for the t-case. The shifters for the tcase ended up coming up right under the transmission shifter. I had to take these to a machine shop and have them modified. I got a stock exhaust midpipe from a 4x4 and this fit but was a little tight.

Everything is working well. I just have to figure out something to keep the gear oil fumes from coming into the cabin. I will probably get a little piece of thin metal to cover the hole I cut to let the shifters come up. I have a few pics that I will share later but I stopped taking them because I just wanted to work and get it done.

 

search ebay - there are several twin stick rubber boots that will work for this application.

 

Nice!!! Can't wait for the pics!

So would you rather use the adapter or go with the A750F?

 

I think you would have less complications with the A750F. It might would put your sticks coming up in the cup holders instead of under the transmission shifter. And you wouldn't have to worry about cutting the output shaft down. I do not have the tools that are required to do the tranny swap and wouldn't have the room. I did it in a tiny one car garage. But if I had room, transmission jack, and a lift I think the A750F would be the way to go.

 

Sub'd for the pics. Seems like an interesting conversion. Approximately how many working hours did it take?

 

Can't wait to see the final results!

 

Are there any updates after you were able to put some miles on the conversion? I just got my frame replaced and am thinking about starting to gather the parts for the swap.

 

I have about 550 miles on it so far. Only issues are a tear in the axle boot that I have already replaced and tear in the shifter boot. I had to modify the twin stick shifters and I tore the boot that goes on the transfer case when trying to put it back on. I have it bandaided right now as I wait for a replacement to come. I have a little bit of road noise that I want to take care of too.

I have some pictures of the tail shaft and why it has to be cut down and the need for the adapter on the 2wd transmission. I just haven't taken the time to post.

Question for you. I have not had any issue with frame rust because the truck lived in the south up until 6 months ago. Is frame rust something I will need to worry about now in PA and is there anything I can do to keep it from happening?

 

Okay. I finally uploaded the pictures.

This shows the output shaft out of the transmission. You can see it is not splined all the way back to the transmission so a spacer is needed.

This is with the adapter on it. I had to cut a good bit of shaft off with a cutoff wheel.

This is where the twin sticks came up before I modified them. This is right where the automatic transmission shifter is. I have the shifters in place now but I still have some finishing up to do with the leather boot and all so no finished picture of that yet. I also have different knobs from RST.

If you have a transmission jack or something that can serve the purpose I would recommend using the 4wd transsmission. It will cost less because you can resell your 2wd tranny and you will not have to do some of the modifications I had to. Stock drive shafts will work, the twin stick shifters (if you are going with a manual t-case) will come up in the front cup holders giving you a lot more room to play with, and you do not have to worry about cutting the output shaft. You will probably save a good bit of time. I also used a stock y-pipe from a 4wd and it fit just fine. That was easier for me than modifying the existing y-pipe.

Let me know if anyone has any questions. I can also take more pictures of the finished project if anyone wants a specific picture.

 

Wow this is awesome! Great work man.

 

Nice work, glad to see another successful swap. I'm hoping to start mine early next year. I still need a few odds and ends.

 

A video of the truck in action would be pretty awesome, well done all your homework is very helpful. Maybe they'll sticky this?

 

I bought my truck in CA and then moved to Baltimore, MD for 7 years and then Indianapolis for the last 3 years. If they salt the roads in your area, it might become an issue later on. If your truck is registered in PA, I'd call the dealer and see if it qualifies for a frame inspection. If it passes, Toyota will apply a frame protectant and extend the warranty for 5 years.

My frame didn't look too bad but the problem area is on the inside of the drivers side frame rail next to the catalytic converter.

 

Thanks guys! Before this the only thing I had done to a vehicle was change the oil. When I first started thinking about doing the conversion and talking with people about it, most told me I would never be able to do it so I used that as motivation.

I just contacted my dealership today. This recall lasts until March 31, 2016. After that you are on your own. I, like most people, am waiting on an update about the leaf pack. I am wanting to do a small lift so I might just replace them when I do that because I have heard Toyota will reimburse you for it.

 

After skimming through this thread I wasn't able to find a "in the ball park" total. Mind me
Asking what it cost you? Great work man, very inspiring to say the least!

 

Front that pic, I see you didn't use a 4x4 transmission tail, maybe that is why you had to cut your shaft.

How did you end up with shift levels position in cabin?

 

Thanks! I ended up around $4500. It was fun to do but I would not want to do it again. Of course it would be easier the second time.

The 4x4 tail housing is not pictured here but I did use it. A tail shaft on the 4x4 transmission is much shorter and splined all the way back. The second picture shows the adapter that I had between the transmission and the tail housing. You have to use the adapter and 4x4 tail housing and also cut the tail shaft down by about 5". Don't quote me on that measurement. I'll take a picture of the finished project so you can see the transmission, adapter, 4x4 tail housing, and transfer case all in.

The t-case shifters came up right under the automatic transmission shifter so I had to modify it a bit from what is in the picture. I had to cut a hole in the cabin floor to allow them to come up.

 

How's it going!?

I just got my truck back after it was at the dealer for 3 TSB related things. The one being the frame. I knew it was fine when I bought it, and my truck has been in the lancaster area since its first owner.
They thoroughly coated it in their corrosion inhibitor. And I don't even see any rust anymore! Just thought I'd share my expirience with the frame and TSB.

Any pics of your truck all buttoned up!?

 

- I am doing mine next year 2017. Do you have a list or part numbers of everything you purchased?

 

Free-king awesome build. Writing down your username so I can offer you free beer and pizza in a few years when I decide to do this down at my place in VA.

Seriously, though - awesome job.