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SafetyDang DC Build/4wd Swap/Manual Trans Swap Thread

Discussion in '1st Gen. Builds (1995-2004)' started by SafetyDang, Nov 4, 2012.

  1. Nov 4, 2012 at 4:48 PM
    #1
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    I'll just turn this thread into everything..

    [​IMG]

    All Research info is at TTORA

    http://ttora.com/forum/showthread.php?t=146517



    Truck:
    2002
    Toyota Tacoma
    Double Cab
    V6 4 speed Auto
    Prerunner


    Current Parts:
    5 speed Manual Transmission - $250 Birthday Gift
    J-Shifting T-Case - $75
    Front Drive Shaft - $50 Shipped
    Rear Front Portion Drive Shaft - $75 Shipped
    T-Case VSS - $75 Shipped
    J-Shifter Lever -$39 Shipped
    J-Shifter Knob - $10 Shipped
    5 Speed Shift Knob - $25 Shipped
    Clutch Pedal Assembly - $25 Shipped
    Front Diff 4.30 - $264 Shipped
    Non Add Diff Output Tube - $114.50 Shipped
    Master Cylinder - $67.78 Shipped
    Slave Cylinder - $37.78 Shipped
    Marlin Twin Stick - $199 (Plus Shipping 10.51) Bought With Trans Mount
    Marlin HD Transmission Mount 85.00 (Plus Tax 25.49)
    2002 Toyota Tacoma ECU 89666-04010 - $125 Shipped
    URD 5vz Short Shifter On Sale - $106.41 Shipped
    Manual Hubs Spindles - Package Deal $500
    Manual Hubs - Package Deal $500
    Manual Cvs - Package Deal $500
    4.10 Front Diff - Package Deal $500
    Shift Boot And Plate - $39 Shipped
    2004 MT V6 Flywheel - $300
    Diff Drop Bolts - $31 Shipped
    Clutch Hydro Lines and Brackets and Nuts/Bolts.
    31481‑04030
    90931‑01112
    31482‑04040
    31484‑35240
    90461‑12413
    90468‑08046
    91611‑F0812
    $63.32 Shipped

    Current Total Cost So Far 2592.79

    After Selling some of the things I don't need $2347.88



    I'll Update as I go.

    Helpful Links:
    Auto to Manual Swap Junglecode Write Up

    Drive Shaft Measurements

    Double Cab to Manual Swap, Advice and Pointers

    Other Members Conversion Threads

    HillBilly_Young01 Auto DC to 4x4
    Tacoma4Life - Auto DC to Manual 4x4 (5 speed Manual Swap)
    Snorkie Auto DC to 4x4 (Output Shaft Swap)
    SAR_Squid79 Auto Ext to 4x4 (Using Inchworm)
    Interex Auto Ext to 4x4 (Output Shaft Swap)
    iceman601 Auto 4-runner to 4x4 (Using Tacoma Trans/T-case)


    FAQ


    What do I need to swap to a 5 speed transmission?
    R150 or R150F (4x4), Clutch, Clutch Cover, Flywheel, Transmission or T-case mount, Slave Cyl, Master Cyl, Clutch Lines, Shift Boot, Shift Cover and a few other little bolts and nuts.Source


    Would a 4x4 Single Cab front portion of the rear drive shaft work for my Double Cab or Extra Cab? No Single Cabs drive shaft is shorter then a Double Cab or Extra Cab. Source


    Can I use parts from a 4-Runner? For a Tacoma you can use 4-runner parts from a 3rd Gen 1996–2002. Source

    If I do a Auto to Manual swap will I throw a CEL? Yes unless you swap out the ECU for a 5 Speed 4x4 Manual. Source

    Can I reuse my Pre-runner Transmission for the swap? You have 2 options you can choose from. One is to swap out the 2wd output shaft for a 4x4 output shaft. Two run the Inchworm Prerunner Adapter Plate with a Gear Driven T-case or a Lefty Adapter with a Lefty T-Case. (NO Stock T-Case w/ Adapter)
    Sources: Output Swap Prerunner Adapter Plate

    Can I use my Prerunner Vehicle Speed Sensor? No, They are different. Source

    Can I use my Prerunner Rear Drive shaft? Yes but the front portion after the Center Carrier Bearing must be shortened 12" Inches. Source

    If I use Manual Hubs will I keep my ABS? Only way to keep ABS on manual hubs is to press the Manual hubs into your ABS spindles. Source

    Will a T-Case from a Manual transmission bolt to an Automatic transmission? According to ShowStop "input shafts are different lengths between auto and manual" Source 1 Source 2 *Update According to js_iron "They are the exact same output shaft length and they both will bolt right up to the A340F" Source


    Can I use a 2.7 T-Case for my 3.4 Transmission.

    Can I use ADD CV's with my Manual Hubs? No, the ends are different.Source

    How do I wire up my clutch cancel button? "If you want the clutch start safety feature with over ride switch, best to cut it out of the wrecked truck harness and piggy back onto your DC harness." - mattm94 Source Post #18

    First Collect Some Parts..

    T-case
    [​IMG]
    Transmission
    [​IMG]
    Front Drive Shaft
    [​IMG]
    Rear Drive Shaft
    [​IMG]
    T-Case, Transmission, Rear Drive Shaft, Front Drive Shaft
    [​IMG]
    Clutch Pedal From a 98
    [​IMG]
    J-Shift lever
    [​IMG]
    Some Shift Knobs
    [​IMG]


    --------------------------------------------------------

    Clutch Location
    My Brothers 5 Speed Extra Cab (Mind The Grease)
    [​IMG]
    My Double Cab
    [​IMG]

    Cross Members Are in the same Locations for Double Cabs and Extra Cabs

    Auto Double Cab PreRunner
    [​IMG]

    5-Speed 4x4
    [​IMG]


    Install Manual Hubs and Diff....

    [​IMG]

    [​IMG]

    Broken.... =[

    [​IMG]

    Bam!

    [​IMG]

    Messing with the springs on the Hubs..

    [​IMG]

    Done

    [​IMG]


    Do Needed Mods...

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Sealant part number.
    [​IMG]

    Cleaning it up.
    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    [​IMG]

    Shift Knobs bugging me... They never lined up right..
    [​IMG]

    Off to modding them... little spacers...
    [​IMG]

    Bam! Lined up!
    [​IMG]


    Waiting for Amsoil Transmission fluid and my LCE 38lb Flywheel has not come yet...

    Bam...

    [​IMG]

    [​IMG]

    Got bored.. Eye balled it.. Luckily I got it dead on!
    [​IMG]

    Cleaned the T-Case w/ Twin Sticks :D
    [​IMG]

    Test fit, make sure I got the right T-case..
    [​IMG]

    Installing URD Short Shifter
    [​IMG]
    [​IMG]
    [​IMG]
    [​IMG]

    Cleaning..
    [​IMG]

    [​IMG]


    Deciding where to bend or cut the Twin Sticks
    [​IMG]

    Clearance Problems in Reveres and 2nd and 3rd Gears.. In low.. or 2wd
    [​IMG]
     
    Last edited: Aug 26, 2014
  2. Nov 4, 2012 at 4:48 PM
    #2
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    [​IMG]

    [​IMG]
    Remove Drive shaft

    [​IMG]

    [​IMG]


    Remove Transmission Drain Plug

    [​IMG]

    Drain...

    [​IMG]

    2wd tranny still there...
    [​IMG]

    Remove Clips... Clips.. And More CLips!

    [​IMG]

    [​IMG]

    [​IMG]

    Making a mess...

    [​IMG]

    Flex plate

    [​IMG]

    Ghetto Transmission Jack..

    [​IMG]

    [​IMG]

    Cut my exhaust because mine no longer had flanges to unbolt..

    [​IMG]

    Unbolt....

    [​IMG]

    [​IMG]

    SuperChiem may use this for the RV... Needed a Speed Sensor.

    [​IMG]
     
  3. Nov 4, 2012 at 4:48 PM
    #3
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Removing Transmission Lines
    [​IMG]

    Passenger Side

    [​IMG]

    [​IMG]

    [​IMG]

    Driver Side

    [​IMG]

    [​IMG]

    Removing torque converter
    [​IMG]

    [​IMG]


    Got to the flex plate



    [​IMG]

    OEM Clutch lines...

    Master Down... I think I may have to move my Master Cyl up a little bit.. But we will see...

    [​IMG]

    Moving Brake Booster Wire
    [​IMG]

    [​IMG]


    [​IMG]

    Connecting the Master To the Flex Hose
    [​IMG]

    Flex Hose to Slave Line

    [​IMG]

    End of the Slave Line came with this plug... Hm....

    [​IMG]

    Which gave me an Idea...

    [​IMG]

    Condom!

    [​IMG]
     
  4. Nov 4, 2012 at 4:49 PM
    #4
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    :saw:
    [​IMG]

    :saw:

    [​IMG]

    [​IMG]

    Found a broken stud in the bell housing..

    [​IMG]

    Removed the bell housing.

    [​IMG]

    Tried Vice Pliers
    [​IMG]

    Drill...

    [​IMG]

    Tap... didn't come out... :mad: PO had it like this as well, but I wanted to fix it...

    [​IMG]

    Also Cleaned the Bell Housing

    Before:
    [​IMG]

    After:
    [​IMG]

    Installed the LCE 38lb Flywheel.. torqued to 63 lbs

    [​IMG]

    Installing the clutch pad.. Fat side is the flywheel side,

    [​IMG]

    The SST should come in and out easily...

    [​IMG]
    [​IMG]

    [​IMG]

    Then it rained... and I had class

    [​IMG]

    What Fluid to use...

    [​IMG]
     
  5. Nov 4, 2012 at 4:49 PM
    #5
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Spot Saver
     
  6. Nov 4, 2012 at 4:49 PM
    #6
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Maybe 1 more spot saver..
     
  7. Nov 4, 2012 at 5:04 PM
    #7
    dually

    dually Low and slow

    Joined:
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    Member:
    #8205
    Messages:
    3,127
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    Interstate underpass
    Vehicle:
    05 Indigo 4wd Longbed
    Not as many as the 98..
    I just swapped my 2wd.. this looks more extensive haha
     
  8. Nov 4, 2012 at 5:05 PM
    #8
    Stubbs95tacoma

    Stubbs95tacoma Well-Known Member

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    Wichita
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    6 Inch Lift
  9. Nov 4, 2012 at 5:09 PM
    #9
    Steves104x4

    Steves104x4 Well-Known Member

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    Steve
    Buffalo NY
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    2010 RC 2.7 4x4
    BUCKLE UP! It makes it harder for Aliens to pull you out of your Truck.
  10. Nov 4, 2012 at 8:57 PM
    #10
    GentryGoon

    GentryGoon Well-Known Member

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    Colorado
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    TRD PreRunner
  11. Nov 4, 2012 at 9:09 PM
    #11
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Should finish up in the next week or so if time works with me.
     
  12. Nov 5, 2012 at 5:44 AM
    #12
    85GT 79FJ40

    85GT 79FJ40 Well-Known Member

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    Ken
    New Hampshire
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    05 SR5 Double Cab 4X4
    I love the grease on the spring. I did the same thing on both the 95.5 and 98 I had previously to shut them up. Kudos for taking this on. I know a lot of people are scared of this kind of stuff and advise others to just buy another truck. If my auto tranny in my 96 starts to give me issues I'll be swapping a 5 speed into it. But mine's already 4WD so I won't have quite an extensive parts list.
     
  13. Nov 5, 2012 at 5:57 AM
    #13
    Madjik_Man

    Madjik_Man The Rembrandt of Rattle Can

    Joined:
    Dec 2, 2009
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    Boulder, CO
    Vehicle:
    1998 Ext Cab 4x4 TRD 5MT sunfire red pearl
    About 25 pounds of spray paint and vinyl dye
    Now this is how you make a walkthrough. While I will never have to do this swap, thank you for taking the time to detail it.

    And I agree with mbassman. Ditch that torsion spring in the clutch pedal and go with a brake return spring.

    I doubt your DC has the welded tab behind the dash to hook it on to, but it seems like you might be somewhat mechanically inclined to figure something out :laughing:
     
  14. Nov 5, 2012 at 6:14 AM
    #14
    isu2014

    isu2014 RAT Products

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    Farmington, MN
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    01 SUPERCHARGED TRD OR MANUAL 4x4 V6
    View the build. Too much to list.
    I'm so jelly! I want a 5 speed.
     
  15. Nov 5, 2012 at 9:19 AM
    #15
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    I was planning to do the spring thing never got around to it. Doing more on Thursday...
     
  16. Nov 5, 2012 at 9:30 AM
    #16
    Blackdawg

    Blackdawg Dr. Frankenstein

    Joined:
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    Monte
    Wyoming/St. Louis
    Vehicle:
    96.5 FrankenTaco & 03 Stock dbl cab
    BFG KM2 33x12.5 tires, Wheelers Type B rims, Allpro 1.5'' Wheel spacers w/extended thread lug nuts 2 Alpine 10'' Type Xs 2 Kicker 6X9s 4 Sony 5 1/4s Pioneer 4100 HU Sway bar removed 4 Hella 500 HIDs Frankenstein Leaf packs 1'' lift shackles Eibach coils 5100s front 10'' 5150s rear BAMF BPV bracket Deckplate mod Elite Front bumper Magnaflow 14'' muffler Elite Off Road Rear bumper with Tire gate with jerry can and fold down table, BAMF sliders, Custom Homemade Bed, rack/roof rack, CVT Mt. Shasta Roof Top Tent, 20lb CO2 tank, BAMF diff skid custom front skid, GM CS144 140 amp alternator Blitzpro 21s HAWK side LEDs Blitzpro Custom made side mirror lights, LightForce 240 Blitz llights, Piaa 510 ION fogs, XRC8 Winch w/in cab controls,
    :popcorn:

    sweet project man!

    only way id want a tacoma is with a 5 speed. Id do this..or try..haha
     
  17. Nov 5, 2012 at 9:54 AM
    #17
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    You'd be surprise what double cabs have. They have the mounts for the clutch hydro lines and some mounting hole for the clutch peddle. I'm sure its down there.
     
  18. Nov 8, 2012 at 6:16 PM
    #18
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Updated
     
  19. Nov 8, 2012 at 6:56 PM
    #19
    Blackdawg

    Blackdawg Dr. Frankenstein

    Joined:
    Dec 31, 2010
    Member:
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    Messages:
    50,537
    Gender:
    Male
    First Name:
    Monte
    Wyoming/St. Louis
    Vehicle:
    96.5 FrankenTaco & 03 Stock dbl cab
    BFG KM2 33x12.5 tires, Wheelers Type B rims, Allpro 1.5'' Wheel spacers w/extended thread lug nuts 2 Alpine 10'' Type Xs 2 Kicker 6X9s 4 Sony 5 1/4s Pioneer 4100 HU Sway bar removed 4 Hella 500 HIDs Frankenstein Leaf packs 1'' lift shackles Eibach coils 5100s front 10'' 5150s rear BAMF BPV bracket Deckplate mod Elite Front bumper Magnaflow 14'' muffler Elite Off Road Rear bumper with Tire gate with jerry can and fold down table, BAMF sliders, Custom Homemade Bed, rack/roof rack, CVT Mt. Shasta Roof Top Tent, 20lb CO2 tank, BAMF diff skid custom front skid, GM CS144 140 amp alternator Blitzpro 21s HAWK side LEDs Blitzpro Custom made side mirror lights, LightForce 240 Blitz llights, Piaa 510 ION fogs, XRC8 Winch w/in cab controls,
    I also found that my 2wd I4 cab had a lot of stuff for the 4wd V6 cab..some..was missing a lot too..
     
  20. Nov 8, 2012 at 7:07 PM
    #20
    SafetyDang

    SafetyDang [OP] get your facts straight

    Joined:
    Apr 9, 2009
    Member:
    #15759
    Messages:
    374
    Gender:
    Male
    First Name:
    Dang
    Anaheim, CA
    Vehicle:
    DC with 4x4 & MT Conversion
    Swapped to Manual Trans & 4x4
    Wouldn't make sense for them to change the cab.. Especially since Toyotas all about flow in the factory. Having 2-3+ lines for different cab configurations. IE ( Manual/Auto ) would slow them down especially if its just a different mounting bracket. This is the Toyota Production System (TPS) at work.. "Producing high-quality vehicles as efficiently as possible".. or so they say.
     
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