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4th gen manual swap thread

Discussion in '4th Gen 4Runners (2003-2009)' started by Diego, Nov 8, 2020.

  1. Nov 8, 2020 at 9:42 PM
    #1
    Diego

    Diego [OP] New Member

    Joined:
    Aug 27, 2018
    Member:
    #6906
    Messages:
    10
    Gender:
    Male
    First Name:
    Diego
    Norcal
    Vehicle:
    White 4th gen 4runner
    Hey guys I'm manual swapping my 4runner and I'll continue to update here.

    The parts I'm using
    Transmission from a 2009 Tacoma
    Clutch assy, flywheel all from a Tacoma.
    Clutch pedal and lines from Tacoma.
    Transfer case from a 2019 trail edition 4runner (basically just a manual fj case)
    Input shaft from a manual Tacoma tcase.
    Ecu from a v6 manual Tacoma
    Probably will need more along the way

    Here's the car in it's auto state

    upload_2020-11-8_21-35-9.jpg

    Step one was to disconnect all the wires off the old trans and tcase which wasn't too bad, disconnect cooler lines and support the trans with a jack. Than I unbolted all the bellhousing bolts and had my buddy kick the shit out of the trans untill it separated from the motor.

    Here are the two transmissions next to each other
    upload_2020-11-8_21-43-51.jpg
    If you look closely you can tell that without the tcase the auto is only 2 inches approx longer than the manual trans which means rotating the offset cross member (which bolts right up to the manual) will work flawlessy with no modification.

    Next I began to disassemble the transfer case from the Tacoma to remove the input shaft. The transfer case on tacomas fj cruisers and 4runners all have the same bolt pattern the only difference is the spline count and orientation on the input shaft. I'm using a transfer case out of an automatic car that has part time 4wd. So the shaft must be swapped.
    That's about the point im at right now as of November 8th 2020 because I'm waiting on the clutch to arrive but tomorrow I'm going to crack into the fj case to swap the input shafts and marry the tcase to the trans.

    Today I swapped out the input shafts and it was a massive pain in the ass.

    upload_2020-11-9_19-49-24.jpg
    And here is the old 4runner input shaft
    upload_2020-11-9_19-50-19.jpg

    November 12th
    Finally got the clutch flywheel and pressure plate mated up. Stabbed the trans and bolted up the cross member. Im super happy that the cross member actually bolts right up. Tcase mounted right up to the trans and I got started on the interior.

    upload_2020-11-13_11-46-33.jpg
    upload_2020-11-13_11-47-3.jpg

    upload_2020-11-13_11-47-44.jpg

    I still don't have the clutch pedal in due to me really procrastinating on it. But today I got the car to start by removing the neutral safety switch off the automatic transmission and plugging it into the harness and switching it to park. It starts and runs fine with only two engine lights for the trans. The ecu from a 6 speed Tacoma is entirely different from the 4 runner one and requires repinning and I might get around to doing that if the car hates what's happening but if the auto ecu does fine I'll just run it.
     

    Attached Files:

    Last edited: Nov 13, 2020
    TriaxT4R, y=mx+b, Roody and 2 others like this.
  2. Nov 21, 2020 at 2:09 AM
    #2
    moridin2002

    moridin2002 New Member

    Joined:
    Nov 20, 2020
    Member:
    #18001
    Messages:
    1
    This looks very intriguing, but do you have to worry about smog inspection? If you do, have you checked with your local referee to make sure it will pass with the transmission swap?
     
  3. Nov 21, 2020 at 4:06 AM
    #3
    Spare Parts

    Spare Parts New Member

    Joined:
    May 13, 2020
    Member:
    #14274
    Messages:
    163
    Gender:
    Male
    Southern Maine
    If the 4Runner was a manual, I wouldn’t have my taco. Good luck.
     
  4. Nov 21, 2020 at 7:37 AM
    #4
    POOLGUY

    POOLGUY New Member

    Joined:
    Aug 16, 2016
    Member:
    #2481
    Messages:
    157
    Gender:
    Male
    First Name:
    Jeff
    Vehicle:
    '08 4RUNNER
    Sub’d.
     
  5. Nov 21, 2020 at 9:25 AM
    #5
    Diego

    Diego [OP] New Member

    Joined:
    Aug 27, 2018
    Member:
    #6906
    Messages:
    10
    Gender:
    Male
    First Name:
    Diego
    Norcal
    Vehicle:
    White 4th gen 4runner
    The car is driving now and only has trans codes. The smog shop In town passes me with long tubes.
     
    POOLGUY likes this.

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