2003 4 Door Auto To Manual Swap!

@Malek understood on the glass breaker. I'm not sure It's needed for me, but it's not a bad idea in total. Thanks for the clarification. I can't wait to get this project started. I'll most likely get the donor rig this week and begin disassembling what I need off of it, however I'll be in Japan for the next month-ish so it'll probably be a March project

 

Enjoy Japan! Once you get going, you’ll see it’s a pretty straightforward swap. Good luck!

I’m jealous you pulled a full up donor. I was in the trenches cross-referencing part numbers for whatever 4Runners and Tacomas were in the local junkyards at the time.

 

That's how I started this process but I found the perfect donor, same year, same interior color, same exterior color, same engine with electronic throttle body, same E-locker, and everything I need for the swap... did I forget to mention that the donor has a supercharger? We can have that conversation later

 

SNEAK PEEK

 

Hell Yeah dude!! Glad to see more people doing the swap. Best decision I made with my tacoma. I got a donor, mine did not come with a supercharger though lol but honestly the swap is pretty easy other than the physical labor part. And if you are good with electrical then wiring up for the reverse light and clutch start switch will be easy. I may still have the wiring diagram if you look at my swap thread. I linked all other threads and stuff that I used for doing the swap.Crowe’s Auto to Manual 01 1st gen SwapJust be mindful that if you plan to use the transfer case that is currently with the auto, you will have to swap out the input shafts in the transfer case. Auto and manual are slightly different sizes. I made that mistake since my auto had the J-shift and the donor had the push button style. I wanted to keep my J-shift case so I just bolted it right up, but didn't realize that the input shaft going from the case to the trans is just a hair larger for the auto than the manual. It drove but I was hearing a little play and after pulling it back out again I saw the difference. Swapping the input shafts isn't too bad but it's kind of a pain. But good luck on the swap dude! You'll never go back lol

 

@Ccrowe323 T-case input shaft sleeve swap should just be able to heat up the manual one and slide it off, right? I feel like I've had to do this once before but I don't remember..

 

No, I don’t believe it’s a sleeve. It’s the inner diameter of the Tcase shaft that goes into the trans that is different. I had to open up both cases and swap them, wasn’t too difficult but still took a couple hours on the bench. But again, it’s only if you are using your T-case from your auto trans. If the donor truck has the Tcase you want already mated to the manual trans then you’re all good and don’t need to worry about it.

 

Based on the first post in this thread, posted by @turbodb , the diameter of the t-case input shaft should be the same. Just the length of the sleeve is different? Or am I misremembering this? I swear I've done this before at some point.

 

Just looked at that thread, you are correct in that the length is different. Honestly I never noticed that when I did mine lol, but back when I did the swap and noticed the difference in Tcase shafts, I tried to put the manual Tcase shaft into the auto trans to see if they are interchangeable and it wouldn’t fit over the splines of the auto. So it is both different diameter and length.

 

I just put an auto J case mated to a 5 speed and worked fine. Haven't gotten to offload with it yet but the case goes in and out of gear fine. Only thing I noticed was different shaft lengths. Spline count and diameter were the same.

 

I was able to drive with mine fine, but I felt some sloppiness and could hear a little clanking and that’s what led me to look and notice the difference. I used my auto Tcase for the swap at first and it fit and drove but when I tried to mate a Tcase from a 5speed to the auto it doesn’t fit. saying that the input shaft of the Tcase from an auto is just barely larger, not enough for it not to drive, but I wouldn’t feel comfortable putting any type of real load on it but a Tcase from a manual won’t mate to an auto

 

Pulled the supercharger off today and will be pulling the trans, t-case, driveshaft(s), clutch pedal assembly, and clutch hydros tomorrow. Can someone let me know how to wire up the 2 switches on the clutch pedal assembly? One of them is surely for the clutch start cancel, what's the other one?

 

Have you wired this up yet?

 

Update: Already had a URD short throw shifter so that's nice! Rear driveshaft needs a new carrier bearing but the joints feel OK.

Still need to order a clutch kit & flywheel. I'm thinking LCE - thoughts?

 

Update: I ordered the clutch kit and flywheel pictured above. I also ordered OEM flywheel and pressure plate bolts, the Marlin Crawler heavy duty shift cups for the shifter, and the shifter centering springs. Hopefully everything is here this week, I'd love to have this project started over the long weekend.

Still waiting on an update on how to do the clutch-start-cancel wiring. To quote myself from post #52: Can someone let me know how to wire up the 2 switches on the clutch pedal assembly? One of them is surely for the clutch start cancel, what's the other one?

 

@BossFan did your cruise control work with the new ECU?

 

I’m just throwing this out in the dark but could the other switch be for canceling cruise control if you push the clutch pedal in?

 

That would make sense.. I don't use my brain sometimes

 

Search bar: https://www.tacomaworld.com/threads/tacoma-manual-trans-swap-wiring-help.362316/
One is for NSW or neutral safety for starting the truck ( clutch pedal is pressed all the way; the CSC switch cancels this) the other (clutch peddle not depressed) is for "clutch engaged" to cancel cruise if equipped.

you can use an auto ECU and just jumper the neutral safety switch wires and the truck will act as tho the CSC is always on and the cruise will not cancel with clutch being pressed.

 

@Bandido thanks for the info on the switches, you're the man.

As far as the ECU is concerned, I pulled the one from the M/T donor