Pre runner 4x4 Swap DONE!!

Ok guys, I have finally converted my Prerunner with an Auto to a 4x4 with a 5 speed. The swap was relatively easy and did not take very long. The only thing I have not figured out is how to get the VSS working. I did not take as many pics as I meant too but if anyone is considering this swap feel free to pm me any questions.

Here she is on the lift, having this lift made this swap 10x easier.


Here is the A340E removed from the truck. This may be the most involved part of the swap. You have to take your time and make sure that you disconnect all the wires and lines from the auto. My torque converter stuck to the flywheel and when we pulled the trans, fluid went everywhere, just a heads up.

These are the two cooling lines for the A340. After removing the hard lines, I cut down the rubber hoses and connected them. This seems to be a simple method that works fine.

Here is the new clutch flywheel with new bolts. i ordered new flywheel bolts from LCE Performance out in Cali.

Here is a closer look at the flywheel, this was right before I put the pilot bearing in. I used an old socket that fit the bearing correctly and just tapped her in.

The crossmember will require some fab work. My friend did the cutting and welding on this X member and so far it has worked perfectly.

Here is the A340E and W59/T-case next to each other. I ended up separating the W59 and t case for the install.

Here is the x member reinstalled with the W59 trans. I should mention that the trans goes in very easily when the t case is not attached. We may end up welding a piece on the rear of the x member for added support.

The front section of the drive shaft was too long, so I bought a stock section from a guy off the forum. But we cut and welded the shaft like this just so we could move the truck. I do not recommend shortening a shaft this way, its not ideal.

Here is the finished shaft out of the truck and then installed. This shaft actually drove great with zero vibration. My friend did the cutting/welding and this shaft was within a 1/4" of the stock replacement.

This is the new shaft, bolted right up replacing the welded shaft.

This is the clutch pedal installed, I will try to get a pic of the master cylinder on here soon. I had a stencil from a friend who did this swap earlier so I was able to just mark the holes for the master cylinder, drill, and bolt it right up. I ended up shifting the pedal to the left a tad to help clear the brake pedal.

Here is the interior of the truck now, ignore the wires, they are a work in progress. The drive feels like a completely different truck with the 5 speed. The motor feels stronger and doesn't struggle off idle like it used to.
Sorry for not having pics of the front end swap, I did it by myself and did not take any pictures. But it is very easy. The spindles swap out quickly and the front chunk drops right in as it would on a 4x4 Taco. The front end had 4.10's and my stock rear had 3.91's so I got a complete third member from a friend and swapped it into my truck. I chose to go with manual hubs, they are simple to set up and the t case I bought was from a '97 Taco with lockouts. I still have not figured out the VSS yet so if anyone has any ideas I am all ears.
This is the first actual modification I have made to this truck, but there will be several more to follow.This swap was well worth the time/money. It took about two days and cost around $1200. If anyone has any questions on any of this let me know.

 

Well done sir!

 

Jealous! Like that 79 ford on boggers in the back too lol

 

Have you kill your cell light properly and reconnect your backup light to function normally?

 

Damn dude, should have done this on a 4 door. Good job though! Looks like a lot of work.

 

The backup lights will work, once I splice the wires from the neutral safety switch. Right now the switch is locked out in park and attached under the cab. And my friend did this swap on a four door which made it a lot easier for me because he knew the whole process. It ended up being a fairly easy swap and I only wish I done it earlier. Thanks for looking and glad you guys like it!

 

Thanks for including the cost, but is a 5 speed swap required as well? Also, how much technical knowledge did it require? Sweet build.

 

What do you mean required? I didn't have to do a 5 speed swap to make my pre runner a 4x4. It wouldn't have been much cheaper to keep it an auto. I just prefer a 5 speed and had the parts available. And if you've worked on a truck before, this swap is fairly easy. The 4x4 swap was almost too easy, the frame has all the holes for the diff and the spindles take no time at all the change. Now if you run ADD, that could add a challenge but nothing to bad. The trans swap was very easy, just swap flywheels and bolt up the 5 speed. Running the clutch pedal was probably the hardest part, and that was just because there is zero room under there where the pedal attaches. This swap took me about 10-12 hours, split over a couple days.

 

Welcome to the club.

 

I plan on doing the same swap soon! But did you get the ECU from the truck you parted out and replaced that too?

 

Just curious, why not just buy a 4x4?

 

Subd.

 

Did the transfer case have a mechanical speedo (cable) that you swapped in? If so you just need a vss converter piece. Marlin, low range and probably others sell them. 30-50 bucks, easy fix. I am using one after swapping to 5 speed and am using 87 geared tcases. Nice job too. Agree on both accounts, removing the auto was a huge PITA and running the clutch hoses.

 

No, I didn't have a donor truck, just picked up parts here and there. I still have the auto ECU, which means the truck throws a check engine light. It's throwing 4-5 codes all relating to be auto Trans which is no longer there. Is spent effect the way the truck runs at all.

 

That's exactly the problem I ran into. Thank you so much, I'll be checking on that immediately. And yeah, that auto was a pain, all the more reason to get rid of it.

 

Can you get a 2000 4x4 Tacoma for $1200? There aren't many Taco's floating around north MS and most have high mileage and have had a rough life. This swap was cheap, relatively speaking, and easy to do. And I had all the tools and know-how to get it done so, why not do the swap? Plus it was kind of fun and makes the truck sorta unique.

 

What did you find is the best way to get the clutch pedal bracket lined up correctly?

Edit: just saw the stencil remark. NVM

 

The amazing thing is I went from ~32" bfg KOs, 4.10 gears at like 19mpg highway in a otherwise stock truck with the auto to 35" KO2s, 3 link front, same gears but the R150 manual and only lost about 2mpg highway. Oh and 3" more height. My final drive considering tire size is short now than with the 32/auto combo.

Here it is.

http://www.lowrangeoffroad.com/toyo...cal-speedometer-vss-adapter-301447-1-kit.html

 

Thanks for putting up the link. Just Grabbed one for my 4 door swap

 

If you can't get a hold of a stencil, I can try to send you a copy of the one I used. Made the clutch pedal install somewhat easy.