4x2 to 4x4 conversion

Hello Everyone!

I have a 2002 Tacoma TRD 4x2. Which I’m looking to convert to a 4x4. I know it’s probably be cheaper and better to sell and buy a 4x4. However, that’s not an option. I have an idea of what parts I need to buy, but I’m stuck. My truck is a v6 engine 5ve-fe. I found the proper transmission for the engine what I’m having trouble with is the transfer case. I’m looking for the mechanical J-shift TC. However I can’t find what year it was made or a code to try to find it. Or even if it will work with the transmission I need. Second Let’s say I go with the new Button style I can’t find a wiring diagram or harness.

Any information will be a huge help. Thank you all in advance.


Parts I know I need:
4WD Transmission
Transfer case
Front differential
CV axle shafts
Manual hub
Wheel hub bearings
Front drive shaft
Rear drive shaft
random bits and tools

 

Welcome to TacomaWorld. Can't do it right now but I'll add a few links to swap threads shortly. I'll also add what I ended up tracking down. There are many pieces to the puzzle.

I'd stay away from the push button ADD route and just stick with manual hubs. Just makes it so much easier - planning and parts hunting.

Where are you located?

 

Yes, I 100% agree Manual hubs are the way to go. I’m located in Cypress, Ca (SoCal) Thanks! I’ll look out for the links and parts list.

 

Swap threads/related posts here on TW (in no particular order, just grabbed from my bookmarks) -

https://www.tacomaworld.com/threads/1st-gen-transfer-case-identifcation-for-replacement-swap.753707/

https://www.tacomaworld.com/threads/4x4-conversion.450370/#post-13204258
https://www.tacomaworld.com/threads/prerunner-to-4x4-write-up.501237/
https://www.tacomaworld.com/threads/matthews-jade-green-4x4-conversion-and-other-upgrades.579846/
https://www.tacomaworld.com/threads...ap-w-twin-stick-and-shift-kit-and-b-s.562405/
https://www.tacomaworld.com/threads/4x4-conversion-option.612465/page-2#post-20861795
https://www.tacomaworld.com/attachments/a340-series-repair-manual-with-transfer-case-pdf.4342681/
https://www.tacomaworld.com/threads/safetydang-dc-build-4wd-swap-manual-trans-swap-thread.247243/

2.7 4WD conversion
https://www.tacomaworld.com/threads/4x4-conversion-2-7-doublecab.784492/

For anyone who is interested in sticking with ADD , take a look at this and at his thread -

Want to convert to AWD?? Take a look at this genius approach to bringing AWD to the Tacoma - (his post is here)
https://youtu.be/SfeeqsrEszY


Online sellers I've purchased from and some others which I've had bookmarked -
https://www.ebay.com/str/spaldingautopartsinc - purchased a transmission from them
https://www.ebay.com/str/yotaautoparts - purchased a front diff from them
https://www.ebay.com/str/toyautomart - grabbed a front driveshaft from them, others here on TW have used them extensively. Definitely take a close look at their offerings.
https://www.ebay.com/str/whiteyswrecking - haven't purchased from them but they were recommended to me. Give them a look.


**NOTE** Be weary and definitely do your research on potential transfer case candidates (as well as transmissions). I've had one seller label a transfer case as from a specific VIN and it turned out to be completely incorrect. A lie? Have no way to prove it. Point being, do your homework. Use https://www.toyota.com/owners/my-vehicle/vehicle-specification to plug in the VIN and comfirm its what you're looking for. Check pictures carefully.


Toyota OEM part suppliers - my current "Go-to" suppliers
https://partsouq.com/en/catalog/genuine/locate?c=Toyota
https://parts.toyotaofcoloradosprings.com/

HELPFUL to have
Factory Service Manuals (truck and trans)
A which can also be used to help support/guide the front diff into place
A will make life so much easier
Socket extensions (1/2 and 3/8), extensions and more extensions

Special Note Trans/TC removal
When pulling and reinstalling your transmission, please take note of the torque converter bolts. There is one bolt which is different from the others (black or green). This bolt is installed FIRST. See this TSB for full info.
If you need a video to watch (lol), here you go.

A word on parts...
Need to decide if you want to spend the extra money on OEM parts or save a bit and go with aftermarket. Some have gone with aftermarket hubs/wheel bearings and have had no issues. There have also been some reports of problems with aftermarket hubs and bearings. If you end up sourcing steering knuckles out of a salvage yard or from another source, you should be able to re-use the manual hubs. I would still replace the bearings (which will require a shop press or pay someone to do it for you) and I personally would go with OEM bearings/parts).

@zippsub9 is someone to touch base with also. Awesome dude to do business with and top notch quality. https://www.tacomaworld.com/threads/for-sale-4x4-manual-hubs-spindles-knuckles-and-cvs.709082/

Many of the threads I linked above have a 'parts list' of sorts in them as well so watch for them and bookmark for later reference.

When it comes to wiring up the transfer case indicator lights, be sure to take a look here -
https://www.tacomaworld.com/threads...dicator-light-and-a-t-p-neutral-light.783875/

If you have questions, shoot me a PM and I'll try to answer them. Putting together the parts you'll need is the most time consuming. There will be setbacks but don't give up. Once you have everything on hand, install goes really quick.

Cheers!

 

Thanks! This is great information!! I’m slowly buying up the parts I need.

 

If did a similar swap in my 02 if you have any questions

 

Too bad you’re not closer

https://omaha.craigslist.org/pts/d/omaha-toyota-tacoma-4wd-conversion-parts/7526173605.html

 

I would highly recommend going OEM for the hubs and wheel bearings

 

Looking for a t-case right now, solid axle swap in six weeks.