2nd Gen Tacoma Auto to Manual Conversion

I will try and use this post to document some of the progress of my transmission swap. And hopefully help the next person out with their swap. Regardless if your truck is V6 or 4 Cylinder, 2wd or 4wd this should help your project.

My truck started life as 2005 SR5 V6 Automatic double cab long box. I will be installing a R155F from a 2011 4cyl 4x4. And eventually FJ transfer case.
I won't be providing a whole lot of info on the ecu/electrical requirements as I will no longer be using the 1GR-FE engine. Instead I will be using 2.0 TDi engine. (Information regarding the TDi swap will be compiled in a different post)

After cruising the forums and Google I have compiled some more information to add to what is available for 2nd gen automatic to manual swaps.

Here are some more posts from others who have went auto to manual
- https://www.tacomaworld.com/threads/2009-4-0-auto-to-manual-swap.662601/page-7#post-27835319

- https://www.tacomaworld.com/threads/2-7l-2wd-auto-to-manual-conversion-guideish.678091/

- https://www.tacomaworld.com/threads/2006-tacoma-auto-to-manual-swap.756181/#post-26955101

-https://www.tacomaworld.com/threads/auto-to-manual-swap-progress.792584/page-3#post-28399751

-https://www.tacomaworld.com/threads...-gen-e-brake-swap.800827/page-4#post-29279709

 

Clutch Pedal

This is the automatic parking brake mounting pad, it needs to be removed. A dedicated spot weld drill bit makes quick work of this task.


This is the firewall from a OEM manual transmission truck, take note of the firewall brace for clutch pedal.



This is where I chose to drill holes for the hydraulics and pedal mounting studs. I got a bit aggressive when drilling out the spot welds, and chose to fill the holes with some rivnuts. Which I eventually used to mount the pedal brace....Happy accident as Bob Ross would say. The holes that the studs come through are larger than one really needs them to be. I had originally installed rivnuts to mount the clutch pedal. I later removed them when I chose to install a firewall brace.



This is my firewall brace, it's kind of crude and was a "proof of concept/prototype" that will likely end up being permanent unless I decide to perfect it.
It is just a piece of 2" x 1/8th" flat bar about 7" long and a second piece about 4" long in the center. Idea behind this was to distribute force evenly across the high and low points of the fire wall.







Booster back in, featuring a "I drilled through the fire wall so I'm going to fix it with a rivnut"

Many manual transmission owners complain about having a squeaky clutch pedal. One of the fixes is to install the FJ cruiser clutch pedal components, if you are hunting for parts it may be worthwhile to use the FJ pedal assembly right off the Start.

 

BRAKE PEDAL

 

Parking Brake
The parking brake is another time consuming part of the swap. After looking at couple manual trucks, taking measurements and going through pictures online of the factory parking brake mechanism mounting. I began to try and replicate the factory mounting position of the parking brake.
On the OEM manual trucks there is a mounting point on the bulk head, and a raised standoff on the firewall for the mechanism to bolt to.
Both of these index the mechanism at angle downward and slightly towards the passenger.


Firewall on the Automatic truck.

Firewall on OEM Manual Transmission Truck.
Parking brake on OEM Manual Truck
This is currently what I have to mount the mechanism to the bulk head. This may change, if I end up tweaking the spacing of mechanism from firewall.


I once again chose to use rivnuts to attach the mechanism. They are easy and fast, if you have the right tools. Also beats welding to thin metal and burning paint.

I had some plastic spacers in a junk bin that worked perfectly for the time being, I may end up changing how far/close the mechanism sits from the firewall pending my final installation of the TDi throttle pedal.
When I finalize it's placement I will update pictures.


Parking mechanism installed for now .

 

Transmission


Rockauto lists two separate part numbers for the R155f and the A750f transmission mounts likely because of the extra weight of the automatic . I currently have the R155f installed utilizing the A750f transmission mount.

Pictured below is the new (aftermarket) r155f mount compared to the used OEM A750f mount.









The A750F and electronic shift transfercase that came with the 1GR-FE. Weights 270lbs without fluid.



R155f installed waiting on adapter plate to arrive to finalize everything else

 

Electrical

 

Parts

This will be mostly be just a dump of various exploded view screen shots. For reference purposes more than to provide part numbers.








6speed Hydraulics

5speed Hydraulics

With VSC

Without VSC

FJ Clutch pedal

 

Hydraulics
I was able to get a Tundra brake booster and master upgrade from the local "You Pull Junkyard". Doing so prevents me from using the OE tacoma master cylinder reservoir with clutch port. I considered using the OE external reservoir found on trucks with VSC. But I chose fitting a reservoir from a 09ish Honda as it was $5 from the junkyard. The OE Toyota parts from the dealer were was to rich for my blood.

 

Drive Shafts

As of right now, the V6 DCLB Automatic drive shafts are exact fit for the R155F with the VF2BM transfercase.

It appears the V6 Automatic, 4Cyl Automatic and 4Cyl 5 Speed all share the same front driveshaft, with a compressed length of roughly 28.5"
The V6 6speed uses a shorter front drive shaft with a compressed length of 27.5 "
This should be good news for anyone going from auto to manual with a 4cyl 4wd, one less expense.

 

Have u got the trans mounted in yet?

 

Yup, r155f trans is in with the tcase off the a750f. a750f drive shafts, and r155f mount. 4wd trans cross members are the same across the 2nd gen platform

 

Did the t case bolt right up to the r155?

 

Yup, no issues.

 

Any chance u have a pic? My buddy doesn't believe it lol

 

I'll try and get some pictures uploaded in next day or two.

 

Looks like it’s coming along good. I didn’t build a brace for the clutch pedal mount like you did. I think I will go back and redo mine. I was concerned about it flexing the firewall over time. I was nervous for the e brake assembly before reading your post about installing it. Might be more nervous now hahaha

 

I added a link to your swap in my original post.

 

Any updates?

 

@dkensk Just curious how you did your wiring (clutch start cancel, reverse, neutral if you did that, etc)?

 

I haven't got that portion finished, but I will likely repin everything to match a factory manual truck.

I did a bit of a career change and put the swap on back burner. Now with winter here, I will start to work on it again. Hopefully post some more updates next month.
I also added yours to my original post