SafetyDang's Slow Tacoma Build

[safetydang]

I finally had a chance to sit down and sort my build thread out.

Had it since new:

2002 Toyota Tacoma Prerunner V6 3.4L Auto

Wheeling it stock!




Left the truck stock for a long time till about 2007. Then installed some adjustable 5100 Bilsteins all around.



I later upgrade to Donahoe Coilovers in 2009
Please note that this is a later picture hence the front axle and upper control arm.



What a world of difference these coilovers make. Here I am in Barstow, Ca "jumping" my truck.



I then added a cheepo front bumper, Yakima Roof rack, and Colmen basket.



Got some Hella 500s for the front bumper. Wheel at Main Divide once again



And here we are at Pismo Beach, CA






Some how my Hella 500s broke and I had to remove them just before going to Barstow again.



Continued to run the truck as is for a while till I found a great deal on Donahoe Control Arms.



What a joy it was to have so much travel. Finally got to do the Mojave trail, still have yet to explore all of it. Here is me getting stuck, still 2wd but I installed a Posi Trac Locker and 4.30 gearing.



Mojave River Crossing!



Didn't do much wheeling for a while. Got a new bumper and welded it on.



Got a used Bud Built skid plate few months after that.



Found an awesome spot for my shovel behind the rear seats.



Remounted my Scan Gauge II by the speedometer.



Was then very annoyed by the front carpet moving around. The stock tab just came off. So I made a bracket to hold them in place.



The stock seats where brutal on my back. So I swapped them for some Scion XB seats!



Here is a video kind of showing how I did it. Which started a Youtube Channel called SafetyDang TV. LINK

 

[safetydang]

Then Mojave again!








With in the same month I decided to run the same trail. Was itching for some wheeling!












During that trip I found that my leaf springs where done and my truck needed rear bump stops.




Shock Relocation

My trucks nude!

Grinding for "boxing plates" for the cross member

In the garage about to weld the "box plates" on the frame. :welder:

Here is my bottom weld.

Top Weld

Tried again, didn't fit had to regrind some more!

Let my brother weld it up.

Tacked the bottom shock tab

1 shocks in and flexing it out to find Bump

Everything in working order

 

[safetydang]

Whats next you say? Well I really got sick of getting stuck. So I decided to swap to 4wd swap. Which also brought me to researching a 5 speed manual swap. This started long ago and was finally starting to make some real progress.




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

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

Broken.... =[

 

[safetydang]

Bam!




Messing with the springs on the Hubs..

Install front differential, axles, and manual hubs.

Done

Do Needed Mods...

Sealant part number.

Cleaning it up.

Shift Knobs bugging me... They never lined up right..

 

[safetydang]

Off to modding them... little spacers...

Bam! Lined up!

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

Bam...

Got bored.. Eye balled it.. Luckily I got it dead on!

Cleaned the T-Case w/ Twin Sticks

Test fit, make sure I got the right T-case..

Installing URD Short Shifter

Cleaning..

Deciding where to bend or cut the Twin Sticks

Clearance Problems in Reveres and 2nd and 3rd Gears.. In low.. or 2wd

 

[safetydang]

Remove Drive shaft

Remove Transmission Drain Plug

Drain...

2wd tranny still there...

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

Making a mess...

Flex plate

Ghetto Transmission Jack..

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

Unbolt....

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

 

[safetydang]

This is one long thread!

Removing Transmission Lines

Passenger Side

Driver Side

Removing torque converter

Got to the flex plate

OEM Clutch lines...

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

Moving Brake Booster Wire

Connecting the Master To the Flex Hose

Flex Hose to Slave Line

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

Which gave me an Idea...

Condom!

 

[safetydang]

:saw:

:saw:

Found a broken stud in the bell housing..

Removed the bell housing.

Tried Vice Pliers

Drill...

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

Also Cleaned the Bell Housing

Before:

After:

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

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

The SST should come in and out easily...

Then it rained... and I had class

What Fluid to use...

 

[safetydang]

Pictures from the past 2 weeks of work. Sorry been busy.. DRIVING IT!

So last week. I put my throw out bearing on, fork, and torqued everything to specs per fsm.

Loctite

Grease

More grease...

Little bit more..

I got my friend.. to help me out... Toyota Tech Eric!! (hes basically a Master Tech) just to assure things don't go wrong.

Then I forgot about the shift tunnel and short shifter..

Bam.. :saw:

Then again!

Cross member almost didn't go in but then I found a way to make it fit.. Esp if you have the Heavy Duty mount...

Cross member first! Not bolted but in the "grove" or "slot" and note not all the way up as well. Then slide the mount in. Once you get that far push cross member up and and bolt that down. Finally bolt the MOUNT to the Cross member. And the hardest part was bolting the mount to the transmission.. Careful not to strip anything! Take your time.. Use pry bars or even the tranny jack to line everything up.

Put the starter back..

Then the exhaust.. OH BOY the exhaust... Everything came out ok but going in.. one nut striped my stud.. Some how got the nut off and cleaned up the threads enough to get a new nut on. If I ever have to take it off I will replace it...

Cleaning drive shafts..

Getting some air leaks in the shift tunnel.. The plate is about 1 inch or 1/2 inch short.. Duct tape was used as a temporary fix.

Twin stick boot helped limit the air coming in.

Replaced the plastic "cover" that was near the manifold with this clip.. Which bolts on to the clutch slave line to flex line bracket.

Then started marking what the hecks what..

 

[safetydang]

VSS Pig Tail

Reverse Sensor on Passenger side of transmission. (Use Tacoma4Life Diagram. (I didn't wire that yet)

O2 sensor Plug

O2 sensor pig tail

Taped up the rest for now..

Remove Auto transmission bracket

Looking through the wheel wheel you can see the bracket it clips on to.. And how close it would be to the manifold. Looked on SuperChiem's truck and he has a heat shield type from factory..

Well then..

Donor..

Boom!

Learned how to solder correctly in Basic Automotive Electrical.. Using J hooks on each end then twist gives you the best connection.. I've been crimping everything before I learned this..

Solder

Wrap

Other end needs the same thing.

and wraped!!!

What! No more following slow drivers to prevent getting speeding tickets for me!

 

[safetydang]

Code were cleared till I got a p1132.. which is the A/F front sensor. >.< Always something... Though I do have an exhaust leak that I haven't tended to. Other than that the swap took 30mins, Cutting not unpining. Unpin if your not lazy.

 

[safetydang]

Lets see what else happened after the swap..

Tried out Corbea Sport seats, didn't like the back support so switched back.



New front bumper from Trail Gear



New Deaver Expo 8 pack.



Skid Plate Panted so spotter can see



Cleghorn!



Azusa Canyon

 

[scrapdaddy]

Safetydang,

Just read through your build, alot of nice work. Good Job!

Question: On the Corbeau seats, I'm getting the same ones, what exactly didn't you like about the back support. Hurt your back, etc.?

Thanks,

Ron

 

[safetydang]

Safetydang,

Just read through your build, alot of nice work. Good Job!

Question: On the Corbeau seats, I'm getting the same ones, what exactly didn't you like about the back support. Hurt your back, etc.?

Thanks,

Ron

Thanks Ron,

I have to say that the seats were used so take that into account. I have back problems so any discomfort is amplified for me. Felt fine to drive any where nearby, but longer trips killed me. The seats will hug you very well though. I ultimately went back to my Scion XB seats, which sit a few inches higher, has better back support, but less hugs. Link is up top somewhere.

 

[Josie'sLandCruiser]

Hi all,


Wow! Incredible build!! Thanks for sharing with us.

Regards,

Alan

 

[safetydang]

Thanks Alan! Now that all the performance modifications are almost done I can move on to camping equipment.

Sent from my SGH-T959V 2

 

[nocotaco]

Sweet build man! I just swapped the 60/40 bench out my '96 Taco for some buckets out of a 3rd gen 4runner. Those Scion XB seats look sweet though! Do you still like 'em after having them in for a while? Any issue mounting them, or did the holes line up just right?

 

[safetydang]

Thank you sir! The seats are very comfortable and have held up great! Bolts line up because I used the rails from the stock seats. If I were to do it over Id just cut and weld the feet.

 

[southerntaco98]

Hey where did u buy the twin sticks??? I know they are marlin crawler but did u but them from marlin or elsewhere??? Marlin never has it in stock

Sent from my iPhone 60' up in a lift

 

[safetydang]

Hey where did u buy the twin sticks??? I know they are marlin crawler but did u but them from marlin or elsewhere??? Marlin never has it in stock

Sent from my iPhone 60' up in a lift

Got them from Marlin directly. If I did it again I would have went with FROR

http://frontrangeoffroadfab.com/nfoscomm/catalog/product_info.php?products_id=36

Damn, 5-speed double cab. Nice work.

Thank you sir.