2003 Auto to Manual swap

The little clip is circled in red in both the photos below, you can see my clutch hard line clipped into it. It’s pretty hard to see.

 

Cool. Thanks!

 

I need these two dowel pins that hold align the bellhousing to the transmission body. The dowels that align the bellhousing to the engine are still in the engine block.

does anyone know the part numbers for these?

 

Progress update.
Lower ball joints installed/torqued
Lower control arms with KPOffroad alignment kit and Strongflex bushings installed
Flywheel installed (not torqued because I need another set of hands).

I was hoping to get transmission installed this weekend, but I need a clutch pivot ball and a couple of alignment dowel pins between the transmission and bellhousing and don’t think I’ll have them by then.

 

I as re-reviewing the auto to manual swap by @SafetyDang and I noticed that when he was cutting the floor, he had some kind of plate/gasket that I’m assuming goes between the console and the floor. I have it circled in yellow below. Is this part still available?

 

I didn’t end up using that piece, it’s not large enough to completely cover the opening from the auto trans so I modified the cover piece from the auto+transfer case case. I did use the rubber shift boot arrangement from the manual trans+transfer case with some modification.

 

Cut the floor today.


I still need to clean up the edges a bit.

 

Started to install clutch and realized that the shop that resurfaced the flywheel never reinstalled or gave me back the flywheel alignment dowels. So that’ll have to wait now.

 

Progress update:
Got the front end all buttoned up today. Did not have the easiest time getting the bottom of the front strut to line up with the control arm bracket. Wound up using a tractor suitcase weight to help pull it down.

 

I also started working on my wiring upgrade. I bought the Big 7 from ToyotaCables.

 

When I replaced the rear main seal, I used ThreeBond Liquid Gasket Gray 1184 because it is supposed to be impervious to oil. Since then, I’ve read a number of posts and it seems most people use the Permatex Ultra Grey. I I know the Permatex is thicker than the TheeeBond and it has me second guessing myself. I’d hate to get the clutch installed and the manual transmission in the truck only to find the thinner gasket maker was wrong choice. Has anyone else used the ThreeBond with good success?

 

On an unrelated question, my alignment pins for the flywheel, as well as for the bellhousing to transmission, and my clutch fork pivot arrived today. Does anyone know how much I should torque the clutch pivot ball? I didn’t see it in the FSM

 

Got the transmission dnd clutch slave cylinder installed today.

 

I ordered a new transmission mount and I’m probably going to restore the crossmember better, so I’m not going to put shifters in just yet because I’ll have to lower trans again (I think).

I want to swap the 4WD actuator at the back of the transfer case today. The one on the manual has a cracked connector but the one that was on my automatic is in good shape.

5-speed


Automatic

 

I was wondering about that looking at your fly wheel pictures .

Missing all the dowel pins on the bell housing and fly wheel.

I don`t ever remember seeing them listed as separate parts but I never looked real Hard.

Good luck!

 

I still had the dowel pins from the automatic that were in the block. I found the flywheel to pressure plate dowels at partsgeek.com.

 

Progress update:
Today was an electrical day! Here’s what o got installed:

• Starter
• Big 7 cables
• 105 amp alternator upgrade

Cleaned up starter


The upgraded cable is much larger so I used a zip tie to hold the plastic cover in place:


I was able to fit the new cable in the plastic wire loom that runs across the front of the oil pan:

The 105 amp alternator upgrade (from a Suzuki Vitara) requires you to drill out the threaded hole on the ear for the stock adjusting block:

The Suzuki alternator is clocked differently than the stock Toyota one. It will still work, but the wire from the alternator to battery is now on the bottom:


Here’s the new alternator with the Big 7 wires loosely run:

 

Following as I want to do this to my 2004

 

It’s a journey for sure. I should change the name of this thread. It started out as an automatic-to-manual swap but has really morphed into something much bigger. Suspension upgrades, steering rack upgrades, POR-15 frame treatment, wiring upgrade, alternator upgrade…I guess that’s what they call scope creep. lol

I followed @SafetyDang’s thread on his auto-to-manual conversion, and relied on @Adventure Taco for all the other upgrades. Happy to help you out with anything I’ve learned.

 

Thanks man!