'03 Prerunner 4x4/trans swap donor options

Hello folks. This is my first post here so I apologize if I ask something that's been discussed before. I did some searching around but didn't find what I was looking for.
I have an '03 Prerunner, 2.7L, automatic. The truck is in great shape and I like it a lot. I'd really like to do a 4x4, manual transmission swap. Correct me if I'm wrong but I understand that swapping 4x4 parts into a Prerunner is relatively straightforward. This is my first Toyota pickup so I'm really not up to speed on interchangeability.
I'm an experienced mechanic and fabricator so the job doesn't intimidate me. Where I need some help is in narrowing down what year and model Tacoma I can use for parts. I figure the best way to do the job is to start with a donor truck that I can pick up for cheap due to a rusted frame, blown engine, etc.

-Will any 1st gen work or do I need to stick to more specific years?
-Do all motor options use compatible manual transmissions or do I need to stick to a four cylinder model or even a 2.7 specific?
-How about axle ratios?
-Other pitfalls I should know about?

I might be able to pick up a '95 for cheap that could provide me with a lot of the parts. Front axle and hubs, clutch pedal and parts, etc. Any idea if those parts will work?

Thanks a lot.

 

Interesting. I'll shoot you a PM.

 

@BartMaster1234

 

My tips as someone who converted his 1998 PreRunner.

- Keep to manual hubs, it’s a purely mechanic system with no vacuum or electronic intervention necessary. Only found on 1995-2000 Tacomas.
- You must match your rear gear ratio. The gear ratio is found on your VIN sticker with a three digit code, something like B07A which is mine. That’s 4.30 - though a chart can be found on this forum.
- Try and find a mated transmission to transfer case so you don’t have to worry about compatibility issues. Stick to j-shift and not push button 4WD.
- You’ll have to extend your VSS. It’s done by cutting the four wires and extending it 6”.
- The front portion of your rear driveline will be too long. I recommend you have a driveline shop cut and balance it, and have them change the u joints. Cheaper and easier than finding the correct one.
- The front differential, front driveline, transmission & transfer case (if manual/j-shift), from a 1996-2002 4Runner will work. Keep in mind most of these 4Runners will not be manual, but are auto and push button cases.
- For transmissions, you’ll want a W59 for the four cylinder manual. Keep in mind you need a 4WD W59, the W59 also came on 2WD trucks. The R154F is designed for the v6 and stronger, not sure if you can use that.

 

I know @BartMaster1234 had that copy and pasted somewhere

 

Cool. Thanks for the info. So if I understand you correctly the front driveline of the ‘95 that I might be able to get will work with my ‘03 (assuming the axle ratio is the same)?

 

Yes. And if you get the whole truck and the ratios don't match, just use the rear diff from that truck too.