2002 Double Cab 5-Speed/4x4 Conversion - TTORA Forum
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post #1 of 861 (permalink) Old 12-04-2009, 02:40 PM Thread Starter
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2002 Double Cab 5-Speed/4x4 Conversion

Had to start this thread some time might as well start now. Missed out on lots of great deals due to money issues or else I would have been done. Here is the break down.

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

Mods:
Donahoe UCA, Donahoe 2.5 Coilover, Bilstein 5125, Deaver 8 Pack, Snug Top Shell, Yakima Roof Rack, Coleman Basket, Hella 500, Custom Front & Rear Bumper, Cobra 19Ultra III CB


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. $63.32 Shipped
Current Total Cost So Far 2592.79

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


Searching For Parts
Interior Plastics




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

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 19962002. 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

[I]How do I wire the ADD system with out the computer?/I]
Answered by Here


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.
Quote:
Originally Posted by hytenor View Post
I believe 2.7 T-cases are the same, manual/AT. The difference in shaft length is in the tranny, not the tcase.

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

Last edited by SafetyDang; 09-20-2017 at 08:45 PM.
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post #2 of 861 (permalink) Old 12-04-2009, 07:37 PM
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I think I have a vss in my parts bin.

I will be at the Ranch Sunday, I will look around.

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post #3 of 861 (permalink) Old 12-05-2009, 10:22 AM
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Thanks for detailing your work, as I plan in the future switching my auto '02 DC to a manual transmission with a J-Shifter. My only real questions arise with getting the electronics working. What I understand is it is important to try and get the replacement transmission from the same year, as many say the harnesses change from year to year. Good luck and I'll be checking up on your progress!

-luke-

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post #4 of 861 (permalink) Old 12-05-2009, 04:07 PM Thread Starter
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Quote:
Originally Posted by swanky868 View Post
Thanks for detailing your work, as I plan in the future switching my auto '02 DC to a manual transmission with a J-Shifter. My only real questions arise with getting the electronics working. What I understand is it is important to try and get the replacement transmission from the same year, as many say the harnesses change from year to year. Good luck and I'll be checking up on your progress!
Correct, try to get the same year. But there is a thread on how to do a 5 speed swap. Which is what I am following combined with the 4x4 swaps every ones been doing. I am going with Matts Thread for the 4x4 swap info and snorkies. Going to head to the junk yards over winter break. Most likly going to find everything I need then. I updated the first post with the link for the auto to manual swap.
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post #5 of 861 (permalink) Old 12-10-2009, 03:23 PM Thread Starter
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Jomentum just might have a VSS for me! All the clutch items seem very cheap online or on ebay so I'm not to worried about that stuff. Anyone have exp with after market Clutches? or just go with OEM Clutch. Just have to run down to the junk yard to find a clutch pedal assembly. Then I needed the shifters and the rear driveshaft. Damn Finals week. Also updated the first post with FAQ that where hard for me to research. Let me know if you have a question I have everything book marked.
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post #6 of 861 (permalink) Old 12-10-2009, 06:26 PM
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I installed on in my 94 yoyta Truck and It was from Autozone. Life time warranty
Been working great every since I did the swap
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post #7 of 861 (permalink) Old 12-10-2009, 10:55 PM Thread Starter
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Quote:
Originally Posted by swimmerzack View Post
I installed on in my 94 yoyta Truck and It was from Autozone. Life time warranty
Been working great every since I did the swap
How much was it? Ebay OEM seems to go for 200 bucks to 175. Doesn't seem to bad. IDK how much it is from a Dealer though.
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post #8 of 861 (permalink) Old 12-12-2009, 11:02 PM
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question:

are the front portion rear d-shaft lengths different from x-cab autos and manuals???

i ask 'cause i have just done a 4x4 swap from prerunner. i bought a d-shaft BUT, LOW AND BEHOLD.......it didn't fit. it was from an x-cab taco (i didn't see the trans because both t-case and trans were pulled). well, long story, got one from another auto and it worked.

i believe the one that didn't fit was about two or so inches shorter.

are the autos and manuals trans d-shafts different in length?

if so, i've got a front portion rear d-shaft if you need it.

'01 Tacoma PreRunner 4x4 w/some stuff
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post #9 of 861 (permalink) Old 12-12-2009, 11:28 PM
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Quote:
Originally Posted by SafetyDang View Post
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

Just to add to that. Single cab's have single piece rear drive shaft, there is NO carrier bearing and no front and rear piece.

Just saying. ;;



I thought you had more part's then that. Hurry up man !

99 Single Cab 2.7. Finally SAS'd and sitting on full width Toyota axles.
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post #10 of 861 (permalink) Old 12-13-2009, 04:19 AM Thread Starter
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Quote:
Originally Posted by johnnyboy View Post
question:

are the front portion rear d-shaft lengths different from x-cab autos and manuals???

i ask 'cause i have just done a 4x4 swap from prerunner. i bought a d-shaft BUT, LOW AND BEHOLD.......it didn't fit. it was from an x-cab taco (i didn't see the trans because both t-case and trans were pulled). well, long story, got one from another auto and it worked.

i believe the one that didn't fit was about two or so inches shorter.

are the autos and manuals trans d-shafts different in length?

if so, i've got a front portion rear d-shaft if you need it.
Interesting! I'll look into that. How much for it shipped to 92804

Quote:
Originally Posted by Scuba View Post
Just to add to that. Single cab's have single piece rear drive shaft, there is NO carrier bearing and no front and rear piece.

Just saying. ;;



I thought you had more part's then that. Hurry up man !
Thanks for adding scuba! I had parts lined up (Manual hubs, difs, cvs, front drive shaft.) but i found they wont work for my truck so starting over. I just wanted to start the thread to make sure I am doing things right. And to have everything documented.
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post #11 of 861 (permalink) Old 12-13-2009, 09:56 AM
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How much was it? Ebay OEM seems to go for 200 bucks to 175. Doesn't seem to bad. IDK how much it is from a Dealer though.

The whole kit was soemthing like 1 50 or so i belive pluse it comes with "LIFE TIME WARRANTY"
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post #12 of 861 (permalink) Old 12-13-2009, 11:26 PM Thread Starter
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post #13 of 861 (permalink) Old 01-24-2010, 08:01 PM
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Ok.........Did some major digging at the ranch.!!!

I have the Vss with me


Pm sent

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post #14 of 861 (permalink) Old 01-24-2010, 11:36 PM Thread Starter
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Originally Posted by Jomentum View Post
Ok.........Did some major digging at the ranch.!!!

I have the Vss with me


Pm sent
Thanks I get paid friday send you the money then.

Next up Clutch, Clutch Peddle, Master Cyl, Slave Cyl. Would you use junk yard stuff (other then Clutch) be ok or just buy some re manufacture parts.

Last edited by SafetyDang; 02-22-2010 at 02:09 AM.
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post #15 of 861 (permalink) Old 01-28-2010, 11:45 PM Thread Starter
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Finally found a 4.30 front diff non add. and joe found me a VSS. Getting closer..
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post #16 of 861 (permalink) Old 02-04-2010, 11:35 PM Thread Starter
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Thank you Joe! Very nice packaging! My VSS came today. The teeth count is 33 i think Tacoma's are 32 will 33 teeth make a big difference? I know you can swap a gear out, but were do I buy the gear? Answer Here

Thats what Wyatt did here



I was hoping i found a 4.30 front diff for sure but looks like its to good to be true. I wanted to do everything all at once 5 speed and 4x4 but looks like ill just focus on my 5 speed swap now. Trail looks to have OEM clutch parts
http://www.trail-gear.com/clutch.html looks like its fairly cheap just have to go to a junk hard and find a clutch pedal now.

Last edited by SafetyDang; 02-05-2010 at 12:24 PM.
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post #17 of 861 (permalink) Old 02-05-2010, 12:01 PM
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You can find much better prices for clutches on ebay, even with free shipping. Check out the seller 'gripforce'. They also sell AISIN and/or SECO clutches...

-Peter

2002 Double Cab Prerunner to 4x4 swap
2.7 (3RZ) with a 5-speed manual
Manual locking hubs
Aussie Locked front diff
Trail Gear rock sliders
Home made bumpers and skids
Airbag delete/dash swap from a 1997 (because I wanted too...)
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post #18 of 861 (permalink) Old 02-05-2010, 12:15 PM Thread Starter
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Quote:
Originally Posted by Tacoma4life View Post
You can find much better prices for clutches on ebay, even with free shipping. Check out the seller 'gripforce'. They also sell AISIN and/or SECO clutches...
I was reading someones thread about that. Saying they dont always ship OEM Clutches, or it could have been throwout bearing?? I don't remember I'll check that out Thanks Tacoma4life!
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post #19 of 861 (permalink) Old 02-05-2010, 03:23 PM
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I was reading someones thread about that. Saying they dont always ship OEM Clutches, or it could have been throwout bearing?? I don't remember I'll check that out Thanks Tacoma4life!
Your exactly right. Some members will only use Aisin parts, which is what gripforce is supposed to sell. However some have received SECO parts from gripforce. I can't recommend one brand over the other as I just installed a SECO clutch and have had zero issues. But what I'm saying is trail-gear uses both Aisin and SECO as 'OEM' replacements, and I don't know if you get to pick which. So if your indifferent, gripforce sells the same brands for much less. If you do want Aisin specific parts, then I would still contact gripforce and ask directly for Aisin parts, you'll still save a bunch...

-Peter

2002 Double Cab Prerunner to 4x4 swap
2.7 (3RZ) with a 5-speed manual
Manual locking hubs
Aussie Locked front diff
Trail Gear rock sliders
Home made bumpers and skids
Airbag delete/dash swap from a 1997 (because I wanted too...)
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post #20 of 861 (permalink) Old 02-05-2010, 03:28 PM Thread Starter
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Quote:
Originally Posted by Tacoma4life View Post
Your exactly right. Some members will only use Aisin parts, which is what gripforce is supposed to sell. However some have received SECO parts from gripforce. I can't recommend one brand over the other as I just installed a SECO clutch and have had zero issues. But what I'm saying is trail-gear uses both Aisin and SECO as 'OEM' replacements, and I don't know if you get to pick which. So if your indifferent, gripforce sells the same brands for much less. If you do want Aisin specific parts, then I would still contact gripforce and ask directly for Aisin parts, you'll still save a bunch...
Thanks a bunch. Doesn't seem to big of a deal for me. Your thread about the VSS answered my other question too

So if I remember correctly if I use a 2002 (same year) Brake paddle i wont have to replace my brake booster? That was the only reason you swapped yours correct?
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post #21 of 861 (permalink) Old 02-05-2010, 09:24 PM
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Thanks a bunch. Doesn't seem to big of a deal for me. Your thread about the VSS answered my other question too

So if I remember correctly if I use a 2002 (same year) Brake paddle i wont have to replace my brake booster? That was the only reason you swapped yours correct?
I think so. If I were you, when you go to get one, take a look at yours first, then compare. My 2002 had an extra pivoting linkage that the 1997 doesn't have. It's obvious when you see it...

-Peter

2002 Double Cab Prerunner to 4x4 swap
2.7 (3RZ) with a 5-speed manual
Manual locking hubs
Aussie Locked front diff
Trail Gear rock sliders
Home made bumpers and skids
Airbag delete/dash swap from a 1997 (because I wanted too...)
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post #22 of 861 (permalink) Old 02-05-2010, 11:58 PM Thread Starter
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I think so. If I were you, when you go to get one, take a look at yours first, then compare. My 2002 had an extra pivoting linkage that the 1997 doesn't have. It's obvious when you see it...
I'll be sure to check it out.
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post #23 of 861 (permalink) Old 02-14-2010, 07:49 PM
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As far as the VSS goes...do you need to mess with it if you're just swapping the transmissions? I recall reading something about the 5 speeds requiring a different VSS to read your speed correctly...but the details are kind of spotty.

EDIT: Found it in my own thread regarding the multimode 4Runner xfercases that have AWD. Seems to be only a 4runner issue? Post #11.

Looks like i'm SOL on this swap, V6 4runners use ABS to sense speed instead of a VSS .

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post #24 of 861 (permalink) Old 02-14-2010, 08:16 PM
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As far as the VSS goes...do you need to mess with it if you're just swapping the transmissions? I recall reading something about the 5 speeds requiring a different VSS to read your speed correctly...but the details are kind of spotty.

EDIT: Found it in my own thread regarding the multimode 4Runner xfercases that have AWD. Seems to be only a 4runner issue? Post #11.

Looks like i'm SOL on this swap, V6 4runners use ABS to sense speed instead of a VSS .
On 4x4 models, the VSS is mounted in the transfer case. In pre-runners (2x4's), there is no transfer case, so it's in the transmission. The transfer case mounted VSS and tranny mounted VSS are NOT interchangeable.

Also watch out for the older models that use a mechanical VSS to run the speedometer (via a cable) vs the newer electronic type VSS. For 4x4 Tacoma's, all electronic type VSS (1998-2004) are interchangeable regardless of transmission type.

Lastly, lets say you were putting a transfer case from an older Tacoma (ie 1996) onto a newer (ie 2003) Tacoma, you CAN put an electronic VSS in place of a mechanical type. In other words, the opening and internal drive gears are the same in all (1995.5-2004) Tacoma transfer cases. There are however other differences in the transfer cases regarding engine and manual vs automatic...

-Peter

2002 Double Cab Prerunner to 4x4 swap
2.7 (3RZ) with a 5-speed manual
Manual locking hubs
Aussie Locked front diff
Trail Gear rock sliders
Home made bumpers and skids
Airbag delete/dash swap from a 1997 (because I wanted too...)
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post #25 of 861 (permalink) Old 02-15-2010, 07:49 AM Thread Starter
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Thats true.. but for Tacoma's.. He has a AWD 4runner. Hes going to need to do a ECU swap and maybe even then the AWD may not work because he will have to swap his AWD ECU for a 5 Speed ECU. This is because he lives in CA and needs to clear all codes.. An AWD Auto ECU wont have clear codes if he has a 5 speed. So he must swap the 5 speed ECU, only problem is nobody knows if it will through a code with the AWD system. My brother did some reading on a AWD swap for his Tacoma. I'll talk to him about it and see what he found out. The big question is does AWD work as a Stand Alone, meaning with out the AWD Auto ECU.. No codes.. Thats only if your 4-runner has a Electric VSS and not ABS speed sensors.. Then i do not have an answer for you..

Check if there is a Speed Sensor on your T-case or Transmission as well, see if you can run a VSS. I never heard of them getting there speed form ABS.. If your not getting your speed from your abs then another option is to Ditch the AWD system and get a 5 speed with a NON AWD t-case (Tacoma J-shifter) that way your ECU would just be swapped for a 5 speed ECU and you wont have to worry about the AWD ECU System. This will only work if your truck can run a VSS, if it runs a ABS speed sensor then I have know idea what to do..
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post #26 of 861 (permalink) Old 03-01-2010, 04:46 PM Thread Starter
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Updated Pictures of Parts

T-case

Transmission

Front Drive Shaft

Rear Drive Shaft

T-Case, Transmission, Rear Drive Shaft, Front Drive Shaft

Clutch Pedal From a 98

J-Shift lever

Some Shift Knobs



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

Clutch Location
My Brothers 5 Speed Extra Cab (Mind The Grease)

My Double Cab


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

Auto Double Cab PreRunner


5-Speed 4x4
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post #27 of 861 (permalink) Old 03-06-2010, 06:05 PM
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I'll be keeping an eye on this build as I have a prerunner double cab V6 I might convert to 5 speed

-The Brain
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post #28 of 861 (permalink) Old 03-06-2010, 07:28 PM Thread Starter
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Quote:
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I'll be keeping an eye on this build as I have a prerunner double cab V6 I might convert to 5 speed
It is funny, I posted some pictures and my views just sky rocketed. Yet you are the first to post a comment. Matt Young and a few others gave the the inspiration to do my build. If a broke college student like Matt can do a 4x4 swap then why can't I. I being another broke college student. Here is a tip. Start collecting parts now if you find a good deal on them. And before you know it you have all the parts you'll need. So far I almost have all the parts needed for my 5 speed swap. I believe if I had only done the 4x4 swap I would be done. Good luck on your build, and feel free to ask questions as I have all the Threads bookmarked.
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post #29 of 861 (permalink) Old 03-07-2010, 07:04 PM
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What are you doing about the clutch cancel switch? Are you going to just splice in the CC harness in place of the PWR ETC harness?

I really wanna do the swap, but its working out these little things thats making me 2nd guess it.

03 dcab - SAWs, ARB bumper, Alcan AAL, OME rears, 255/85 KM2's, Timbren front/Energy rears, home-made belly pan, Alpine audio, Wheeler's brakelines, home-fab bedbar, deckplate, extended diff breathers, Magnablow exhaust, 6 aux lights, dual spares, etc.

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post #30 of 861 (permalink) Old 03-08-2010, 10:57 AM Thread Starter
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Quote:
Originally Posted by Offroadtaco3 View Post
What are you doing about the clutch cancel switch? Are you going to just splice in the CC harness in place of the PWR ETC harness?

I really wanna do the swap, but its working out these little things thats making me 2nd guess it.
"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." Source: Here (You also posted in there)

I'll be using Tacoma4Lifes wiring method if I do not get the ECU first.



Are smog laws in NJ as bad as Ca?
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