2003 4 Door Auto To Manual Swap!

IT BEGINS

Today's progress

1. Pull out old ECU, install donor ECU
2. Pull both driveshafts (not reusing)
3. Pull T-case (reusing, twin sticks)
4. Pull A340F (FOR SALE)

I've got 2 questions to end the day. First, how did you guys template a hole for the shifters? I need to cut one large hole correct?



Same concept second question, how do I template a hole for the clutch master cylinder? I know it's has to be pretty perfect because it doubles as the stud mounts for the clutch pedal assembly.



Let me know! Thanks!

 

Use the master cylinder to make a construction paper trace out. Then just tape it on that area that has the shape for it and drill out the holes (two mounting holes and one for the clutch).

 

Do I just center it in the divot?

 

Yup, that's what I did.

 

@SafetyDang @BossFan I'm getting ready to drill my clutch master. Do you guys have any tips for keeping the pedals square?

 

Check out my conversion. Not exactly like yours but should give you ideas.

https://www.tacomaworld.com/threads/auto-to-manual-w58-complete-96-taco-2wd.834057/

There is a pic of my master cylinder holes drilled out in my post. If you drill them out just a hair larger you'll have adjustment. But really it centered pretty easy for me.

 

I just checked post #7 on your thread, it looks like the clutch pedal sits lower than the brake pedal - do the brackets line up under the dash? I guess I might have a misconception that the pedals are supposed to be more or less in line

EDIT: I wasn't smart enough to take a picture in my donor before I pulled the pedal

 

If I remember correctly the bolts for the cylinder go through the clutch pedal assembly. Hence everything already lined up. It was easier than it looked.

 

I do remember you might have to swap your big brake pad for a clutch sized one. I've seen other people just alter theirs to get it to work.

 

That is the way they are supposed to line up. Pretty sure.

 

@Mikerocosms Yes, I should have been more clear - my bad

I understand that the studs on the back of the pedal mount are the same studs that mount the clutch master on the opposite side of the firewall. I'm wondering if the pedal mount should be moved "up" in order to keep the pedals more in line with each other and, if-so, does that still allow the clutch master to fit in the divot relatively square?

P.S. you did a great job mounting your trans, that thing is clean as hell

 

FLYWHEEL AND CLUTCH

 

Working on transfer case. Got my input shaft sleeve swapped from the shorter auto version to the longer manual version. Only thing left to do is clean the mating surface and seal it back up

 

Hi, getting the pedals to line up made me want to die


@BossFan @traxman25 Trans mount fit like a glove


Tomorrow:

• Mount slave
• Bleed clutch hydros
• Adjust clutch pedal
• Flush trans fluid & refill
• Mount tcase
• Mount driveshafts
• Skid plate
• Wire in clutch switches
• Mount rubber shifter boots
• Mount leather shifter boots

I have faith I can get it all done in 1-go

 

Using the wiring diagram I got from @osterhagen build, which is also a 2003 double cab (lucky me)

And a diagram I found which includes the clutch start cancel from a 3rd gen 4Runner swap
I have redrawn my harness to match this diagram (I am clearly an artist as you can tell)

As far as I can tell, this wiring will complete the build from a wiring perspective. I had already figured out the reverse wiring switch beforehand, so I'll have to un-do that or re splice it to accommodate the other switches (clutch release, clutch start cancel) that needs power from the black/red wire. Wish me luck I hate wiring.

 

I just did a 4x swap and am looking for a shifter bezel for an automatic, wondering if you sold it already? I am interested..

 

Mine sold with the trans.

 

Wiring done btw. Everything working so far. No CEL
https://youtube.com/shorts/jffZFp7tmFw?feature=share

 

COMPLETE, and cruise control works. Truck shifts like butter on glass