UPDATED - Now with Twin cases and triple sticks "El Taco Diablo" 4x4 swap and B.S.

No problem brother!

Shift kits help keep things cooler and also the crisp shift actually helps decrease wear on parts. (Plus... I've never done one and figured this would be a good time to try it)

I'll get you a measurement flange to flange some time this weekend. It's at the driveline shop now, they ran in to a problem balancing it. (Guess it's to be expected with my luck, and a DL off of Craigslist)

 

Im all about manual. Just how I grew up. All my dads trucks are manual. I just bought a dodge Cummins 5speed and 4x4

 

There were more issues than just cut and re-weld. The DL was damaged. I saw evidence it had taken some hits, but was hoping it was superficial... Turns out it wasn't.

 

There it is... The last part I need.

 

I saw your photo today and it looks good. Maybe you can help me out. I removed the valve cover on a 04 4.0 today. do you know what oil this can be? LOL I just had to share.

 

That looks like it could be oil from the factory... After a lot of miles.

 

oil changes are optional, really

 

Some progress was made tonight.

Got the truck situated in the garage so we can work on it with the door down. (Weather is supposed to be cold and rain the next few days)

Pulled both 2wd spindles

And... What do I see here???

 

mounting that front diff is always a fun time I like how it catches on literally everything

 

So, we made some more progress today.

The front is essentially done. Still have to finish mounting the spacers. But, everything else is done and torqued to spec.




Decided to lose the sway bar while we were in there.

 

For those that are running LC Engineering hard lines with Tundra brakes. You'll have to use 3/8 bushings as spacers behind the mounting bracket to clear Total Chaos gussets. They bearly fit after using the bushing/spacers.



Anything more than 3/8, there's really no thread left for the bolt to mount the bracket to the spindle.

 

Aaaaaand... We got the rear driveline and Trans dropped.

 

Check you rear main seal while your there. Just a few bolts away from it. Looks good! Take your time reinstalling the torque converter and make sure the flexplate is flush against torque converter before bolting down the 6 bolts.

 

So much room when you get the tranny out. What is the dark line from? Looks like something was flinging oil??

 

Awesome day of wrenching today!

MAJOR thanks to:
@FirstTimeFirstGen (for driving all the way from Sac to help)
@Blue Canary
@CalTacoma09
@duncnasty
@Pella
And @foxrcing07 and @BartMaster1234 (for the valuable phone a friend support)

You guys are fricken heros!

Got the rear main seal replaced.

Flex plate torqued... (I would highly recommend cleaning the old thread locking compound on the flex plate bolts, then re-apply red lock tite)

Before

After

We swapped the black dooma-wiget from my old trans on to the new one.

Got the trans in. Torque converter bolts torqued to spec. Starter re-installed and torqued.

We also modified the Tcase by cutting an ear off under the shifter (the ear was where the arrow is pointing)

Had to crack the case open.

We needed to get to this part right here.

There is a pill shaped detent that needs to be removed, that looks like this.

Modifications to the Tcase were to allow this to work.

And we also replaced the 4 bushings on the shifter (from @Brice). Cut the hole for the Tcase shifter, and replaced the bulb with a blue LED from @csjumper2003

 

Hope you got my text. Regarding the VSS, I got a pigtail with the right connector on it from an A340F from @mechanicjon. I cut the A340E VSS pigtail off, and soldered the A340F VSS pigtail on.

The only sensor I had to swap over was what appeared to be a temperature sensor. Smart move swapping your Park/Neutral switch. When my truck had the grenaded flexplate, the shop had to switch some wires around on the VSS for some reason that I never found out.

 

Here is that VSS Pigtail that I used.



And these are the sensors I had to swap. I can't remember which one, but I had to swap the A340E sensor onto the A340F. Other than that and the VSS, everything else plugged in.



Here are those connectors I was talking about. There are three of them with six total wires. Three for chassis ground, and three for ground to complete a circuit. One to indicate when the shift fork in the transfer case is in N, 4HI, or 4LO. All they do is complete a ground. On stock trucks, these are connected to the 4WD Computer. The computer prevents the Differential Locker from activating in any mode besides 4LO. Additionally, it lights up the single 4WD Icon on the righthand side of the instrument cluster.



I was extra, and I wanted my cluster to tell me if I was in 4HI or 4LO. A stock 4x4 Tacoma does not indicate what mode of 4WD you're in. Only a static "On/Off" image of a 4x4 chassis. So I removed the leftmost cluster lens responsible for ABS, RR DIFF LOCK, and CRUISE. I scanned, and remade the lens in Adobe Photoshop to replace the ABS and RR DIFF LOCK with 4HI and 4LO respectively since my truck didn't have either.

I de-pinned some unused cluster connectors, soldered a jumper wire for the ABS flexible circuit, and connected the factory transfer case position sensor harness directly to the pins on the cluster connector that I designated to operate the 4HI and 4LO lights.









If you want it to operate the stock way with the green chassis icon on the right to light up when in 4WD, all you have to is wire I believe the blue connector to the cluster wire for that symbol. Your truck will be wired for the 4WD light already, as was mine even though I was a PreRunner.

Hope you have the A340F dipstick and tube, because that's what kept me from driving the truck for a week since I had to order it new. The A340E tube and dipstick are different. A340F on Left, A340E on Right

 

I dont know if this is going to work for him. The transfer case hes putting it appeared to have an old cable driven vss.

 

We did run in to issues with the dip sticks not lining up. We just swapped the pan (with the lower dipstick) from the old transmission on to the new transmission.