2002 Double Cab 5-Speed/4x4 Conversion

[mosk22rte]

Originally Posted by brandonjenkins

Yeah i can shift through all the gears very easily without even pressing the clutch pedal in. I just pulled the tranny back out spun the inut shaft on tranny and it spins the driveshaft flanges. So it has to be clutch disc, throwout bearing or pressure plate or all 3 maybe, am i right?

When you had the flywheel surfaced, did they cut a step in its face? The center of the flywheel (the diameter of the clutch disc) should sit 1mm or 1.5mm proud of the rest of the disc.

Also, make sure you have the clutch disc pointing the right way (it's directional, and there's an illustration of the correcy orientation in the FSM).

[SafetyDang]

Originally Posted by brandonjenkins

well finished up the swap still have the driveshafts disconnected cranked it up put it in gear and NOTHING happens. Driveshaft flanges dont spin. Im lost im gonna hate it if i have to pull this thing back out. Any suggestions?

Engine running? Both front and rear flange on spinning on the t-case? Where did you get the doner truck from?

[brandonjenkins]

The donor truck is my tacoma that I flipped. I pulled the motor and tranny out of it prolly 1yr ago. I didn't get the flywheel resurfaced. Should I have? The pressure plate seems to be frozen. The truck ran fine and I towed it around to parks and wheeled it often so idk why it want do anything now. I'm pretty sure I had the clutch disc in the right way the cover wouldn't bolt down if u had it the wrong way.

[Mr Tacomi]

Originally Posted by brandonjenkins

The donor truck is my tacoma that I flipped. I pulled the motor and tranny out of it prolly 1yr ago. I didn't get the flywheel resurfaced. Should I have? The pressure plate seems to be frozen. The truck ran fine and I towed it around to parks and wheeled it often so idk why it want do anything now. I'm pretty sure I had the clutch disc in the right way the cover wouldn't bolt down if u had it the wrong way.

T-Case in Neutral?

[mosk22rte]

Originally Posted by brandonjenkins

The donor truck is my tacoma that I flipped. I pulled the motor and tranny out of it prolly 1yr ago. I didn't get the flywheel resurfaced. Should I have? The pressure plate seems to be frozen. The truck ran fine and I towed it around to parks and wheeled it often so idk why it want do anything now. I'm pretty sure I had the clutch disc in the right way the cover wouldn't bolt down if u had it the wrong way.

I can see not getting the flywheel resurfaced if you had it surfaced recently, like within the past 10k miles, but seriously, how often do you plan on pulling the trans? Never again after you solve this problem? Then get it surfaced as a matter of course when you have the option to do so, and every time you replace the clutch disc.

As for the pressure plate being frozen, it would have to be frozen in the "depressed" position, with the plate retracted -- this would allow the motor to spin but no power to be transferred to the trans input shaft. This means when you bolt it to the flywheel it would simply bolt up and you could thread all of the bolts in by hand. If that last part isn't true, then it isn't frozen in the depressed position, and isn't the cause of the problem you are experiencing.

Echoing Mr Tacomi's question: Are you sure you got the shifters in correctly and the trans and/or transfer case aren't stuck in neutral?

[gotblika]

Originally Posted by brandonjenkins

Yeah i can shift through all the gears very easily without even pressing the clutch pedal in. I just pulled the tranny back out spun the inut shaft on tranny and it spins the driveshaft flanges. So it has to be clutch disc, throwout bearing or pressure plate or all 3 maybe, am i right?

I was going to ask about the t-case in neutral too. But he said this.

[SafetyDang]

I think somethings on backwards..

[gotblika]

If everything checks out on the trans/t-case, it has to be the clutch. You need to PM Showstop he'll help you out.

Even if the t-case was in neutral, he wouldn't have been able to shift thru the gears on the trans without pressing the clutch. Right

[brandonjenkins]

ok well just got done putting in a new clutch and taking the truck on a test drive. I went ahead and replaced all of it. I had this clutch put in when i was in iraq back in 07, but it only had around 150mi and 6 offroading trips. But the culprit was the pressure plate being frozen in the depressed posistion like mosk said i could thread all the bolts in by hand but when i bolted the new one on i could feel the springs "loading" as i tightened it down. Thanks to everyone for putting this thread together couldnt have done it without others stories and pictures.

Yeah i need a consol cover but its not on the priority list right now.

[mosk22rte]

Cool! Congrats on getting it running!

How's it drive?

[brandonjenkins]

the truck feels so much more powerful. I hate autos because you cant choose what gear you want to be in. Plus the tacoma auto really takes away from the 3.4. Im running 285s and 4.88s so my rpms are a little high but i really enjoy it my 2nd gear is like a stock 1st.

[SafetyDang]

Sexy.. I've think 3-4 people have finished their swap since I started this thread. Yet I haven't finished HAHAHA. I'm stoked for winter break though!

[gotblika]

Got my clutch pedal installed today. Real happy the way it turned out.

The contraption I made for a spacer between template and firewall. (36 pieces of cereal box)

Template ready to drill.

Pilot holes.

Looks good.

Stud holes 21/64".
G
Hole saw.

[SafetyDang]

Nice!

[Yotaoffroad27]

NICE! 36 pieces of cereal box huh?

[mosk22rte]

Lookin' good.

[SafetyDang]

Birthday wrenching scheduled! 11/30/11

It may rain but oh well!

Question about the water pump. Did you guys just block the tranny cooler line? I ask because a 5 speed water pump doesn't have the transmission lines. They are different part numbers.

[mosk22rte]

Originally Posted by SafetyDang

Birthday wrenching scheduled! 11/30/11

It may rain but oh well!

Question about the water pump. Did you guys just block the tranny cooler line? I ask because a 5 speed water pump doesn't have the transmission lines. They are different part numbers.

Any update, Dang?

Also, FWIW, I didn't do anything with my stock AT water pump, and didn't notice the line(s) you refer to. I did cap off the two trans cooler nipples on the bottom of the radiator, but that was it.

Jeff

[SafetyDang]

Originally Posted by mosk22rte

Any update, Dang?

Also, FWIW, I didn't do anything with my stock AT water pump, and didn't notice the line(s) you refer to. I did cap off the two trans cooler nipples on the bottom of the radiator, but that was it.

Jeff

I thought you guys would just cap it, but no one mentions it.

Water pump and timing belt didn't come in. Put the clutch peddle (20mins) in and did the twin stick mod (2 1/2 hours). Video write up will come soon. We could have done the whole swap but I was drinking a lot. And we started at 3pm. A productive birthday non the less!

[86yota671]

man i read the first post you put up and then thought it was the only thread i needed to read to do my 4x4 5speed swap, but then i saw the 24 pages! kinda makes me not wanna do it lol so much reading!
but i do appreciate the details you put into it.

hopefully by the time i pay the truck off i can have all the parts collected and ready!

[mosk22rte]

Thought I'd bump the thread with one more data point: I passed my California "Test Only" smog test today with no questions and no issues. Passing the dyno test wasn't a concern as the motor runs clean and I haven't done anything to it (yet -- supercharger install coming next, now that the smog is OK ). I was worried that the MT and/or 4x4 swap were going to be a problem, but it passed the visual, so those weren't issues at all. The tech even noted that I had "converted" to manual hubs and that he thought that was cool and a good idea.

That was pretty much the last remaining task on my swap, so I'm stoked -- it's smog legal, and I have the paperwork to prove it.

Thanks again, Dang and everyone, for your help over the last 18 months!

Jeff

[SafetyDang]

im behind.. dang wheel bearing and new job.. I really want a weekend to just work on my swap..

[Wainiha]

You gave us the first sample video for free, like it was crack. Now I'm hooked. Gimme Safety Dang TV.

[SafetyDang]

Originally Posted by Wainiha

You gave us the first sample video for free, like it was crack. Now I'm hooked. Gimme Safety Dang TV.

AHHA You'll get one soon. I gotta do my tierods.

[Yotaoffroad27]

congrats Mosk!

[Damin]

My double cab is mid swap. After looking at the wiring diagram tell I became one with the chair I was sitting in. I called the dealer about some questions I had. I came to a conclusion, swap out the ECU and ground out the N/S switch.

Does that sound about right?

2003 dc 3.4 2wd converting to r151 trans gear driven cases and SAS

[mosk22rte]

Pretty much. Look over the document in my sig if you haven't yet. It shows that there are 18 wires that are connected to the 2003 5VZE AT ECU that don't need to be connected to the 2003 MT ECU. All of the other wires are identical - same wire colors and functions on the same pins in both ECUs. That makes this pretty easy.

If it were mine, I would remove these unused pins from the ECU harness, either by using a jumper harness and clipping those wires -- what I did on mine -- or by removing their pins from the ECU connectors and taping them off. I would do this because I'm paranoid, and I wouldn't want to risk that any of those leads were still hot and might fry or confuse my MT ECU. That's my 2 cents. If you aren't feeling like doing that, you can plug the stock AT connectors into the MT ECU and take your chances.

As for the connectors to the NSW and back into the cab, refer to Tacoma4Life's conversion thread, specifically the paragraphs before and after his excellent NSW rewiring diagram:



Note that the pin numbers and wire colors on his may not match yours, so refer to your FSM wiring diagram and make sure you know which wire is which. That's the best way to do it, IMO, but yes, you can hard wire the NSW and skip the Clutch Cancel switch if you want to.

Good luck!

[Greg_Canada]

Originally Posted by mosk22rte

Any update, Dang?

Also, FWIW, I didn't do anything with my stock AT water pump, and didn't notice the line(s) you refer to. I did cap off the two trans cooler nipples on the bottom of the radiator, but that was it.

Jeff

It's actually not a transmission cooler, it's an oil cooler. Basically it run coolant through a heat exchanger mounted on the side of the block that cools your engine oil. I kept mine when i swapped the auto 5vz into my manual 3vz truck (3vz did not have the oil cooler, just a block off plate)
(it's the tuna can looking thing)

[Damin]

Originally Posted by mosk22rte

Pretty much. Look over the document in my sig if you haven't yet. It shows that there are 18 wires that are connected to the 2003 5VZE AT ECU that don't need to be connected to the 2003 MT ECU. All of the other wires are identical - same wire colors and functions on the same pins in both ECUs. That makes this pretty easy.

Note that the pin numbers and wire colors on his may not match yours, so refer to your FSM wiring diagram and make sure you know which wire is which. That's the best way to do it, IMO, but yes, you can hard wire the NSW and skip the Clutch Cancel switch if you want to.

Good luck!

Will do thanks man..

On a side note: the wrecking yard sent me an A/T ECU and they won't let me return it. So I'm gonna give the AT ECU a try, if it doesnt work il cut the melted computer out of my dash.

[mosk22rte]

I believe it will work, at least sort of, but it's going to be setting multiple check engine lights (CELs) codes due to the missing electrical components in the AT. Not a big deal if it's a trail only rig and/or you live in a state that doesn't do smog or vehicle inspections, but it's something to be aware of.