Yet Another DC Manual Swap Thread

accountant_mechanic_ · May 25, 2025 at 9:29 PM

osterhagen[OP] said: ↑

Next step to getting to start the truck was wiring in the switches so when I pressed the clutch down the truck knows it's safe to start the motor because it thinks it's in neutral. This was a somewhat involved process that requires breaking down the Neutral Safety Starter Switch (NSSW) wiring plug that used to plug into the side of the automatic into several different connections that would serve different purposes.
Here is a pic of where the plug attaches on the auto transmission: You can see the knob where the shifter attaches to change the position of the switch also.

I Personally remove the wiring loom mounts on the drivers side motor and pulled the whole portion of the loom that ran down the transmission, VSS and O2 sensor up out the front of the truck for easy access and more room to make the needed adjustments

I first found all the various connections that were no longer needed because I removed the auto transmission and set them aside. Next I identified and wrapped the wires that would be used as is (02 sensor) and identified and lengthened the VSS (3 wires). I cut down a ways to keep the stock color wires at the connection for any future issues because I didn't have color matched wires (only red and black). Once lengthened these were wire loomed and then wrapped in cloth electric tape. That shit is really awesome stuff!! These connections are made with butt connectors that are heat shrunk, then covered in heat shrink (kind with glue) and then taped, loomed and taped again. They should be 100% safe and secure.

Next I de-pined the NSSW connector and you can see those wires in the picture above and in the close up below:

Important things to note here: Different years use different colors so it's best to double check your wires against the diagram. All of mine matched except one but I was able to confirm via the FSM diagram and via the pin number on the actual plug (I am color blind, so needed a fair bit of help from my GF on this front) that the wire was correct and just a different color. You won't use all of these wires and so I removed the pins from the wires I would be using and taped the rest up and added them to the loom. That way, if I ever wanted to (not that I will) go back, I just have to plug those pins back into the plug. Kind of silly and quite frankly you can just use what you need and cut the rest. Totally up to personal preference.
Here is the diagram for easy reference. This is not mine, I got it via TTORA forums:

Below is a pic of the plugs that connect to the clutch depress switch and clutch release switch along with the wire/pin pre-build if you want to go that route or need to like me because you don't have a donor vehicle.

Lastly a random shot of dinner, a monster and shitty drawn diagram to keep my sanity while I extended the VSS

While the wiring may seem daunting I found it to be one of the easier parts of the swap. It is very well documented and took just a few hours, even with my overkill methods
I ran the wires for the clutch switches and 4x4 light in through the rubber grommet next to the Clutch Master Cyl. They then run underneath all the hard lines for brakes down the inside of the fender well until they meet up with the primary harness that runs to the transmission and transfer case + 02 sensor

Happy to provide any more information or context that may be helpful.
Click to expand...

2003 double cab manual swap in progress, just mounted pedal today. Auto wiring harness, manual ECU (from same year same throttle body donor). Just to confirm, because I am horrible with reading diagrams, BOTH of the clutch pedal switches wire into the old auto neutral safety switch? Will this get cruise control to work?

Have you wired in the clutch-start-cancel button?

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Yet Another DC Manual Swap Thread

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Yet Another DC Manual Swap Thread

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