Swapping Input Shafts for FJ Case for Manual Transmission

Spidermoney54 · Jul 3, 2022

dborrer said: ↑

"No ring gear has to be swapped." I was going to say... WTF, because i sure changed out mine! But then i read further and see that you corrected your comment.. Pheww... (that was simi-fun part of the swap)

Somewhere on TW I recall reading the quote about the Threads aren't fun w/o pics... so enjoy some randoms from my (best yet) swap...

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How did you do the leather shift boot for your shifters, I’m trying to figure out if the Toyota boot will work or if I need to make one

EatSleepTacos · Jul 3, 2022

Spidermoney54 said: ↑

How did you do the leather shift boot for your shifters, I’m trying to figure out if the Toyota boot will work or if I need to make one
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There’s a whole lot of examples in the below thread. Me, I got a generic boot off of Amazon and “sewed” it into my stock boot. Aka poked a few holes and zip tied them together.

https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

$8 Gear Shift Boot Cover,Car Gear Shift Knob Gaiter Boot PU Leather Cover Replacement for

https://www.amazon.com/dp/B07S68934W?ref=ppx_pop_mob_ap_share

Spidermoney54 · Jul 3, 2022

EatSleepTacos[OP] said: ↑

There’s a whole lot of examples in the below thread. Me, I got a generic boot off of Amazon and “sewed” it into my stock boot. Aka poked a few holes and zip tied them together.

https://www.tacomaworld.com/threads/lets-see-your-fj-case-swap.455278/

$8 Gear Shift Boot Cover,Car Gear Shift Knob Gaiter Boot PU Leather Cover Replacement for

https://www.amazon.com/dp/B07S68934W?ref=ppx_pop_mob_ap_share

Click to expand...

I’ll probably take your route with it just needed an idea/

EatSleepTacos · Jul 3, 2022

Spidermoney54 said: ↑

I’ll probably take your route with it just needed an idea/
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The price/effort to finished product ratio is hard to beat imo. $15 and some zip ties and it looks factory at a glance.

Spidermoney54 · Jul 3, 2022

EatSleepTacos[OP] said: ↑

The price/effort to finished product ratio is hard to beat imo. $15 and some zip ties and it looks factory at a glance.
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Agreed

dborrer · Jul 3, 2022

Spidermoney54 said: ↑

How did you do the leather shift boot for your shifters, I’m trying to figure out if the Toyota boot will work or if I need to make one
Click to expand...

https://www.redlinegoods.com/Tacoma05shiftboot.php
I ordered a custom boot from them, and it took multiple emails to get the measurements correct, and it did take forever (but it was actually had made in Poland....).

I also pulled out my insulation from my OEM boot and added to the new custom boot... got to mod new stuff!....

During the wait/order time, i did as EatSleep did below, without the added on boot part.

Spidermoney54 · Jul 7, 2022

just a little kinda cool info, an 84 g52 transfer case shifter fits perfectly tho 6th is still a little tricky you can do it.I’m gonna buy a 1 gen taco t-case shifter the design is the same as the current 4Runner just flipped i believe.

Spidermoney54 · Jul 10, 2022

6 gearT444E said: ↑

the input shaft will need to be swapped from the auto case. They are a smaller 23 spline shaft and the 6 speed is a larger 22 spline input. No ring gear has to be swapped.
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Do you have a write up on the single wire locker anytime mod?

6 gearT444E · Jul 10, 2022

Spidermoney54 said: ↑

Do you have a write up on the single wire locker anytime mod?
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I’m not sure I know what that is? The locker requires 5 wires minimum to operate reliably.

Spidermoney54 · Jul 10, 2022

6 gearT444E said: ↑

I’m not sure I know what that is? The locker requires 5 wires minimum to operate reliably.
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That’s what I was afraid of I’m trying to figure out how to do this without creating a circuit using a diode and relays. I have a harness for the locker I got for my 4Runner that’s just a spare but I wanna use the factory switch and keep my dash light ‍♂️

6 gearT444E · Jul 10, 2022

Spidermoney54 said: ↑

That’s what I was afraid of I’m trying to figure out how to do this without creating a circuit using a diode and relays. I have a harness for the locker I got for my 4Runner that’s just a spare but I wanna use the factory switch and keep my dash light ‍♂️
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here have you, it's 5 wires for actuator function and an additional 2 if you want the light.

BzWires · Sep 15, 2022

EatSleepTacos[OP] initial post: ↑

As some of you may know, RST forums had a lot of good info on there but now all the links are dead. I was able to pull up this page using a web archive machine and I wanted to preserve it for future readers. This is literally just a copy and paste as I have not done this yet.

This is done to swap in a transfer case out of an automatic FJ cruiser into a second gen 6MT.

_________________________________________________________________

There have been a lot of people who have asked if you can make the electronic shifting T case of the current generation Tacoma's into a manual shifting case and although there has been one that I know of that has done it, it is not in my opinion the best way to go about getting a manual t case into the new Taco's.

I have posted up here what I feel is the best way to accomplish this but there are still those that want to see why you can't just stick a lever on this case and make it manual shifting. Because of this I have taken my Tacoma T case apart to show you why it can't be done at least not to my satisfaction.

I also did this because there are those that have the 6 speed Tacoma's and want to put the FJ Case into their trucks. You CANNOT just get a six speed T case from an FJ and swapit into your Tacoma. The six speed FJ case is a full time case with a center differential and it is longer than your stock case. Problems with fitment arise. The best way to do this is to swap the input from your case into the automatic FJ case and then install that into your truck.

First, lets get into the Tacoma case.

From the outside it looks just like the FJ case with the exception of not having any shift levers and and motor hanging from it's rear. But then you open it up an a new world awaits you.

Getting it open is as simple as pulling off the front drive flange and then taking out the twelve 12mm bolts that hold the front half to the rear half.

In this photo you can see the front half has the planetary gears in it and the rear half has the shift forks as well as the hi/lo and 4wd gear sets. Another thing you will notice is that the shift forks are upside from the common configuration of most other Toyota case's and it has one shift rod that controls another internal shift rod. Because of this one rod you would have to rig some sort of lever off of te back of this case t move this rod. The problem with that is once you take the motor off of this case there is an o ring that keeps dirt out and oil in the case that will now be gone. I don't like that option.

This is the inside of the FJ Cruiser T case. Notice that the two shift rods are a the top of the case and not at the side of the case like the Tacoma's is.

This is looking at the planetary gears and the oil pump in the front portion of the case.

Here is the back half of the case and it holds the hi/lo gears, 4wd, as well as the shift rods and forks.

Now, for those that want to put an FJ Case in the six speed Taco's this next section is for you.

If you can't find an FJ Case from a six speed but you have one from the auto FJ, your going to have to swap the input shafts from one to the other. Since they they are basically the same, the easiest way to do this is to just swap out the entire planetary gear set with the input shaft from the front of the case's. This way you don't have to get into taking all those gears off of the input shaft and thats a pain.

First thing you have to do is take the oil pump and pick up off. There are three 10mm bolts that hold the pick up on. Take those off and out comes the oil pick up.

Oil pump behind the pick up.

Oil pick up with screen. You can see some of the sealant that Toyota used on the screen. There is anlso a magnet on the bottom of it to catch any metal particles.

The oil pump once the pick up is removed. There are three 10mm bolts that you need to remove to get it out.

Once the pump is out you can now turn the case over and remove the input shaft cover plate. There are five 12mm bolts that hold it on.

Once that is off you'll see a snap ring that is holding the planetary gearset with the input shaft in the case. Remove that snap ring and the entire gearset will come out of the case through the inside.

UPDATED INFORMATION

In the picture below are the two different input shafts that you'll find in the Tacoma and FJ Cruiser t case's. The huge one is the 22 spline six speed input shaft and planetary gearset and the smaller one is the 23 spline automatic input shaft and planetary gear set. You'll also find the 23 spline case in the 2.7 4 cylinder Tacoma. As you can see the six speed input shaft is huge compaired to the 23 spline shaft from the Automatic transmission trucks. Everything else is the same with the exception of the front plate so they are a simple swap if you know what your doing.

The front of the case minus the input shaft and planetary gears.

Now, when you swap in the six speed planetary gear set into the automatic FJ case your going to need to change the rear ring gear in the planetary gear set or the hi/neutral/lo shifter will not work properly. Following is what you'll need to do for this swap.

Here are the two planetary gear sets side by side. the one to the left is from the automatic and the one on the right is from the six speed.

In the next two photos you can see the big gear. The inside teeth on that big gear are flush on the automatic case but they are stepped down on the six speed case.
The first photo is the automatic and the second photo is the six speed.

There is a big c clip that holds this gear in. You take that c clip off and out comes that ring gear.

This is the gear from the automatic case. Notice that the teeth on the inside are flush with the ring.

Here is the planetary gear set without that ring gear.

Both planetary gearsets side by side. These internals are identical between the two.

These are the two ring gears side by side. If you look close you can see the difference between the two.

And this is the mess you'll have on your work bench when your in the middle of doing this swap.

So there you go. If you are doing an FJ cruiser t case swap into your six speed Tacoma, your going to have to have this done to your FJ case or you'll have to do it yourself. If you go with an RST FJ case, it will be done for you already.

Now, to put the input shaft into the FJ Case you'll need to do to the FJ Case what you have just done to the Tacoma case. Once you have it out you simply reverse what you did and put the the input shaft from your Tacoma Case into the Fj Case and close it up and mount it in your truck.

That's it folks! Pretty simple.
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I have a 07 FJ 6spd and am trying to swap a auto t case into it, is it the same procedure as the taco t case?

BassAckwards · Sep 16, 2022

BzWires said: ↑

I have a 07 FJ 6spd and am trying to swap a auto t case into it, is it the same procedure as the taco t case?
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I think you’re going to need an input shaft from a 6spd Tacoma part time transfer case to swap into the auto trans/part time FJ t-case. I’ve had the 6spd FJ cruiser VF4B transfer case torn apart while building my crawl box, and it is definitely a different input shaft and it won’t work in the auto trans/part time case to be able to put that behind your RA61F.

also your driveshafts will need modifying. The VF4B is an inch longer than the auto trans/part time FJ t-case.

6 gearT444E · Sep 16, 2022

BassAckwards said: ↑

I think you’re going to need an input shaft from a 6spd Tacoma part time transfer case to swap into the auto trans/part time FJ t-case. I’ve had the 6spd FJ cruiser VF4B transfer case torn apart while building my crawl box, and it is definitely a different input shaft and it won’t work in the auto trans/part time case to be able to put that behind your RA61F.

also your driveshafts will need modifying. The VF4B is an inch longer than the auto trans/part time FJ t-case.
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I think that's correct though I've never seen in person. The 6 speed FJ case is a full time case and although the spline count might be the same I believe the interface with the sun gears and differential inside might be different than the part time taco t case. Probably better off sourcing an auto trans FJ t case and putting the 6 speed taco input into it.

BzWires · Sep 16, 2022

6 gearT444E said: ↑

I think that's correct though I've never seen in person. The 6 speed FJ case is a full time case and although the spline count might be the same I believe the interface with the sun gears and differential inside might be different than the part time taco t case. Probably better off sourcing an auto trans FJ t case and putting the 6 speed taco input into it.
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The donor t case is from a auto FJ

6 gearT444E · Sep 16, 2022

BzWires said: ↑

The donor t case is from a auto FJ
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ah ok, maybe I misread your post then. You'll want to source a donor 6 speed input shaft from a 6 speed taco case. I'm sure there's someone on here that probably has one.

BzWires · Sep 16, 2022

Anyone have a input shaft from a 6-speed Taco t-case?

BzWires · Sep 16, 2022

BzWires · Sep 16, 2022

BzWires · Sep 16, 2022

I guess I'm going to have to pull the full-time tcase apart and see what I can figure out

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Swapping Input Shafts for FJ Case for Manual Transmission

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E-Locker do your own.pdf

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Swapping Input Shafts for FJ Case for Manual Transmission

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Attached Files:

E-Locker do your own.pdf

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