1. Welcome to 4Runners.com!

    You are currently viewing as a guest! To get full-access, you need to register for a FREE account.

    As a registered member, you’ll be able to:
    • Participate in all 4Runner discussion topics
    • Transfer over your build thread from a different forum to this one
    • Communicate privately with other 4Runner owners from around the world
    • Post your own photos in our Members Gallery
    • Access all special features of the site

The OFFICIAL manual swap thread

Discussion in '4th Gen 4Runners (2003-2009)' started by Jakobies1086, Jun 7, 2024.

  1. Jun 7, 2024 at 10:25 PM
    #1
    Jakobies1086

    Jakobies1086 [OP] New Member

    Joined:
    Jun 7, 2024
    Member:
    #40944
    Messages:
    5
    Gender:
    Male
    First Name:
    Jacob
    1. I know both the 4spd and 5spd auto's in these 4runners are fantastic transmissions. I know auto's are better offroad and for daily driving. I don't care, I like driving manual.
    2. This is not a 100% step-by-step guide and will require your own part number and compatibility research. You will need your own wiring diagrams and some mechanical ability.
    3. This only applies to 1GR V6 4runners. I'm sure you can do this swap with a 2UZ but it would likely be more difficult.
    4. There's way more then one way to do most of the tasks I'll cover - think outside the box.
    5. It's pretty easy. Time consuming with some custom work required here and there, but overall it's not a difficult swap.


    Candidate - 2004 4runner SR5. 4wd, V6 1GR, 4spd A340 auto, 147k miles.


    Let's get started -

    My trans donor
    - 2013 FJ crusier RA61F 6spd with 150k miles. Any RA61F from a 07-14 FJ will work, but the 11+ RA61F technically has a superseded part number despite being the same externally and having the same gear ratios.

    Other trans donors you can use
    -RA60F from a 05-15 Tacoma. Same a RA61F, expect 6th gear ratio is 0.849 vs the RA61F with 0.799.
    -RA62F from a 16+ Tacoma. Would need modifications for the tcase described here and possibly other things for the swap that I don't know about: https://www.tacomaworld.com/threads/fj-case-in-a-3rd-gen-tacoma.571689/

    Clutch
    -New Luk flywheel and Aisin clutch kit. Ran the Clutch Masters internal slave conversion to simplify the clutch hydraulics and avoid the RA6X Achilles heal input shaft issues.
    -Conventional hydro setup can be used, but I'd suggest at least the URD input shaft repair sleeve.
    -Make sure you buy the clutch kit from whatever year/model trans you buy - even though they all bolt to the 1GR, they have different part numbers and I don't know why.

    My Tcase #1
    -Manual tcase from a 2023 4runner TRDOR. You can use any tcase from AUTO trans 07-14 FJ's or any tcase from 2010-2024 TRDOR 4runners. They are all the same from what I can tell.
    My Tcase #2
    -Any 05-15 Tacoma electronic tcase from a MANUAL. You will need the tcase input housing/shaft to swap onto your FJ/4runner case, as described here: https://www.tacomaworld.com/threads...s-for-fj-case-for-manual-transmission.714337/

    Trans mount - You can use either the manual mount from a Tacoma (Possibly FJ?) or your original 4spd auto mount (Possibly 5spd auto too?). They are exactly the same - both bolt directly to the RA60/1F trans and directly to the original 4runner crossmember with zero modification. Big win

    Exhaust - no modifications needed

    Front Driveshaft - Needs to be shortened 2" in my application
    Rear Driveshaft - Needs to be lengthened 2.25" in my application
    I'm running custom Tom Wood's driveshafts, but I did use a 1.5" Trailgear driveshaft spacer for the rear temporarily to test drive the swap without issue.

    Trans and both my tcases
    IMG_0827.jpg

    Input shaft swap that's linked above
    IMG_0900.jpgIMG_0901.jpg

    End result: part-time 4wd manual FJ Case with the RA6X manual input housing and shaft
    IMG_0908.jpg

    A340 and electric shift tcase next to my RA61F and manual tcase. Note the length differences
    IMG_1005.jpg

    IMG_1205.jpg

    Clutch Masters slave install
    IMG_1209.jpg

    Trans bolted in and primary hole cut for both shifters.
    IMG_1255.jpg
    IMG_1274.jpg



    ALRIGHT - Lets setup the clutch now.
    Clutch pedal assembly from a 2007 Tacoma
    I went ahead and did the metal FJ clutch pedal and metal master cylinder swap into the Tacoma assembly, as instructed here:
    https://www.tacomaworld.com/threads...al-for-a-metal-one-from-an-fj-cruiser.814720/

    IMG_0961.jpg

    Narrow manual trans brake pedal swapped from a manual 2009 FJ, right into original 4runner brake pedal bracket.
    IMG_1077.jpg
    IMG_1078.jpg

    Remove the ebrake pedal - that's gotta go. I removed the complete mechanical ebrake including everything behind the rotors and the cables. I'll be running a line lock as a parking brake down the road. Relocate your ABS control unit while you're in there - I mounted it up against the left side behind the body control unit.

    Once you get in there you'll see this "hump" of metal riveted to the firewall next to the brake pedal. Drill the rivets off and remove it.
    IMG_1080.jpg
    IMG_1081.jpg

    Cut away some of the insulation and bam, your clutch bracket will fit nice and flush on the firewall, You can even use these existing studs/stud locations with minor modifications.
    IMG_1085.jpg
    IMG_1087.jpg

    This is where you clutch lines will go, mark and drill your holes.
    IMG_1086.jpg
    IMG_1092.jpg

    Tacoma clutch res mounted, short hardline section made up and connected to the stainless braided line from the Clutch Masters slave running up the firewall.
    IMG_1405.jpg
    IMG_1094.jpg

    So you trans, clutch, and tcase are ready.

    Let's dig into the console.
    I used a 2nd gen Tacoma console. I wanted an console armrest, functional cupholders, and a good aesthetic. Fair warning, I spent more time making this console setup work then anything else in the entire project. Massive cutting is required to fit the front of the Tacoma console against the angled asymmetrical 4runner dash.

    I cut the top layer wider then the bottom cut of the trans tunnel so I have a flat section to mount shifter insulation. IMG_1254.jpg

    Don't forget to cap the HVAC duct that is running to the rear
    IMG_1361.jpg

    The space where the old 4wd knob was is 60mm after you grind down the inner lip. They do make 60mm gauges, so this would be the perfect spot for one. I opted for a 60mm blank plug, and maybe down the road I'll do a supercharger and swap this out for a boost gauge.
    IMG_1735.jpg

    Note: All 3 OEM Tacoma console mounts retrofitted to the 4runner body. Holes for auto shift cable and ebrake cables plated over/sealed. Shifter boot insulation from a manual FJ cruiser installed. Yaw sensor control unit (required for functioning ABS) harness extended and the unit relocated. Connector installed from cig lighter wires to custom accessories harness on the Tacoma console (USB ports, streamlight charger, etc)

    Trans shifter cut, bent slightly to the driver and rewelded
    Tcase shifter completely custom made to be skinny enough to clean 5th and 6th gear in 2hi/4hi, and not contact the side of the console when shifting in 4L.
    IMG_1790.jpg
    IMG_1792.jpg
    IMG_1793.jpg
    IMG_1791.jpg
    IMG_1804.jpg



    Electronics! Everyone's fav -


    I deleted my front axle disconnect (ADD or CAD) as described here: https://www.tacomaworld.com/threads/how-to-deleting-add-system.427258/
    IMG_1232.jpg

    I wired the Tcase 4wd indicators directly to the indicators on the cluster. Made a little custom harness then used no-longer-used wires from the old transfer case actuator to the now completely removed 4wd module.
    IMG_1268.jpg
    IMG_1270.jpg
    The plugs for the 4wd module which is fully removed. You can see where I used the original 4wd actuator wires as a vessel for the signal lines - jump them directly across to the indicator wires heading to the cluster.
    IMG_1318.jpg


    ***
    The vehicle WILL NOT start if it does not think it's in park. You will need to splice some wires together to do that - you can do it either on the side of the trans where the neutral safety switch was, or inside the 4runner right at the DME.
    At the neutral safety switch connector on the side of the trans you will need to splice pin #9 (pink) with pin #6 (black/yellow).
    If you wanna skip that do it at the DME directly like I did, you would need to splice together connector E4 pin #16 (pink), E4 pin #17 (black/yellow), and connector E5 pin #9 (pink).
    This will likely change between years!! Check your own wiring diagrams. The key is to have to the starting system wires always jumped so the DME thinks it's in park.
    There is another set of "park" wires at the neutral safety switch - pin #1 green/black on my rig. This illuminates the P on the cluster and needs to be separate splices from the aforementioned starting system circuit. I did splice power to it from pin #3 yellow/black under the vehicle in the trans harness, just incase the cluster also needed to see "park" separate from the DME, but I don't think it does. I ended up removing the "P" light from the cluster anyway.

    Splice your manual trans reverse light switch from the power wire (pin #3 yellow black) to the reverse wire (pin #2 red/yellow) at the neutral safety switch.
    ***

    I have not at this time figured out how to make cruise control work, but I will update if I do.



    THE CLUSTER.
    I hate CEL's. You will have a CEL, because the auto transmission is missing.
    I don't like traction control but I also don't like looking at VSC warning lights 24/7 because the system is now disabled with the removal of the trans/4wd module, and the ADD.
    Electrical tape? Sloppy.
    HP Tuners? Expensive, might not work.

    Pop your cluster apart.
    IMG_1322.jpg

    Don't wanna look at the light? Cover the LED with some JBweld putty.
    Also, not pictured, but remove the light transferring plastic over the PRNDL so they wont be receive the amber back lighting everything else does. Won't black them out completely, but it's a lot less noticeable.
    IMG_1323.jpg

    Perfect!
    IMG_1332.jpg

    Remember when we spliced the reverse light switch in? Little bonus - when you shift into reverse your cluster will remind you! Also note - my "P" would be always illuminated if I didn't block it off with the putty.
    IMG_1333.jpg

    4hi
    IMG_1334.jpg

    Tcase neutral - yes I took the time to splice it into the "N" on the cluster too
    IMG_1335.jpg

    4Low
    IMG_1336.jpg

    Running (Well the door is open, but that goes out of course)
    IMG_1815.jpg



    Cool, now go row some gears.
    IMG_1818.jpg
    IMG_1824.jpg
     

    Attached Files:

    Last edited: Jun 8, 2024
  2. Jun 7, 2024 at 10:47 PM
    #2
    scottiezilla

    scottiezilla New Member

    Joined:
    Feb 18, 2021
    Member:
    #19839
    Messages:
    233
    Gender:
    Male
  3. Jun 8, 2024 at 1:08 AM
    #3
    Turbosnail

    Turbosnail New Member

    Joined:
    Oct 22, 2023
    Member:
    #36291
    Messages:
    3
    Gender:
    Male
    Vehicle:
    24 TRD OR / 18 Tacoma SR5
    Fantastic write up , great dedication to detail and doing everything to ensure a professional and user friendly finished product . The Tacoma center console really finishes off the interior nicely . :burnrubber:
     
  4. Jun 8, 2024 at 2:05 AM
    #4
    MI-FL off roader

    MI-FL off roader T4R Hobby/Addict

    Joined:
    Aug 21, 2015
    Member:
    #878
    Messages:
    1,287
    Gender:
    Male
    First Name:
    Brett
    Merritt Island, FL
    Vehicle:
    03' SR5 Sport - 12' Limited
    Too many mods and too much money
    Impressive work and nice first post! You're not going to ask what size tires will rub?
     
    Borracho Loco, GrantA and Turbosnail like this.
  5. Jun 8, 2024 at 2:08 AM
    #5
    Turbosnail

    Turbosnail New Member

    Joined:
    Oct 22, 2023
    Member:
    #36291
    Messages:
    3
    Gender:
    Male
    Vehicle:
    24 TRD OR / 18 Tacoma SR5
    Hey OP , how about some pics of the truck when you get some free time, what other mods do you have planned ? I heard a rumor there could be suspension, wheel and tire and bumper mods in the near future . Post em up !
     
    Last edited: Jun 8, 2024
  6. Jun 10, 2024 at 3:07 PM
    #6
    R4Adventure

    R4Adventure New Member

    Joined:
    Jun 5, 2024
    Member:
    #40894
    Messages:
    67
    Gender:
    Male
    Omaha, NE
    Vehicle:
    2004 Gray 4Runner SR5 V8
    2.5" Bilstein lift, 1" body lift, 34" tires on 17x9 Method Racing 312 wheels, CBI front bumper with Warn EVO10s winch, full RCI under armor and rock sliders, ARB front and rear air lockers, 8.2" rear axle house swap, etc....
    Excellent write up Jakobies1086. You have a very OEM+ look, especially with the Tacoma center console.

    In researching doing a manual swap, I can't loose the ebrake as I do enough off-roading that it's a must keep. Though I had not considered a line lock. I haven't eliminated the option but will be doing the manual tcase here this summer.
     
  7. Jun 10, 2024 at 3:19 PM
    #7
    whippersnapper02

    whippersnapper02 New Member

    Joined:
    Feb 27, 2019
    Member:
    #8982
    Messages:
    2,559
    Gender:
    Male
    First Name:
    Christian
    Vehicle:
    2019 4Runner TRD Offroad Premium
    Awesome work!
     
  8. Jun 10, 2024 at 3:39 PM
    #8
    Jakobies1086

    Jakobies1086 [OP] New Member

    Joined:
    Jun 7, 2024
    Member:
    #40944
    Messages:
    5
    Gender:
    Male
    First Name:
    Jacob
    Thanks for the feedback guys. Truck is a blast to drive, feels like a 2nd gen Tacoma.

    With some firewall and Ebrake bracket modification I think you could keep the Ebrake pedal, just move it closer to the firewall. I opted against that as it seemed like unnecessarily big undertaking in an awkward spot to work.
    Another option I heavily considered was using a 3rd gen manual Tacoma console - the 4runner Ebrake cables T-off on top of the trans tunnel and it would be easy to connect it to the handbrake style lever like found on the 3rd gen console. I opted against this because I couldn’t find a cost effective 3rd gen console and I was worried it would be substantially more difficult too graft into the 4runner due to the difference in vehicle age.
    An honorable mention is the FJ cruiser manual console, which is wider with provisions for both shifters and has a handbrake lever. The downside to that option is it has no armrest console box, because the FJ seats have armrests on them. You could always take this route and try and fit some FJ seats too.

    I ran a line lock to the rear as a parking brake in my old 93 pickup SAS’d crawler, and it was phenomenal. I used a covered single pole switch, a relay, and had it wired to illuminate the parking brake light on the cluster. It’s extremely easy to wire and to plumb, everything is under the hood except the two switch wires running into the cab. It would always hold on extremely steep rock faces so I could get out and spot my line choice, as if I was sitting in the truck with my foot on the brake. I wouldn’t leave it set with the truck off as it will draw on the battery and would release in a low-voltage scenario, but with any manual vehicle I have I always just leave it in 1st with the parking brake off.

    In the 4runner I have the same electrical setup ready to go, but I haven’t settled on the line lock simply because it has a 4 channel brake system so you’d need two locks to hold both rear wheels. Also, it’s kinda tight up there plumbing-wise, so it might be tedious to fit two. I might just a settle with one holding the left front wheel as that would be adequate for 95% of situations I use a parking brake (running into a store with the truck running, taking a piss on the side of the highway, moving cars around my driveway, etc) but I wouldn’t trust it off-road nearly enough without two wheels locked, so I’m also considering doing both fronts as that’s easier to plumb then both rears in the engine compartment.
     
    R4Adventure[QUOTED] likes this.
  9. Jun 10, 2024 at 4:19 PM
    #9
    R4Adventure

    R4Adventure New Member

    Joined:
    Jun 5, 2024
    Member:
    #40894
    Messages:
    67
    Gender:
    Male
    Omaha, NE
    Vehicle:
    2004 Gray 4Runner SR5 V8
    2.5" Bilstein lift, 1" body lift, 34" tires on 17x9 Method Racing 312 wheels, CBI front bumper with Warn EVO10s winch, full RCI under armor and rock sliders, ARB front and rear air lockers, 8.2" rear axle house swap, etc....
    LOSTR4 likes this.
  10. Jun 10, 2024 at 5:04 PM
    #10
    Jakobies1086

    Jakobies1086 [OP] New Member

    Joined:
    Jun 7, 2024
    Member:
    #40944
    Messages:
    5
    Gender:
    Male
    First Name:
    Jacob
    Yeah I’ve seen his swap - that lever sticking way up infront of the console appears to be a hydro Ebrake handle which do not lock on and are for drifting. I’m not knocking it, everything depends on what your standards are and what you want out of the rig - his console has no cup holders, exposed rough cuts, and the poor booting around the shifters is gonna transfer a ton of noise and harmonics into the cabin.
     
  11. Jun 10, 2024 at 5:19 PM
    #11
    R4Adventure

    R4Adventure New Member

    Joined:
    Jun 5, 2024
    Member:
    #40894
    Messages:
    67
    Gender:
    Male
    Omaha, NE
    Vehicle:
    2004 Gray 4Runner SR5 V8
    2.5" Bilstein lift, 1" body lift, 34" tires on 17x9 Method Racing 312 wheels, CBI front bumper with Warn EVO10s winch, full RCI under armor and rock sliders, ARB front and rear air lockers, 8.2" rear axle house swap, etc....
    Yeah, I should have picked up on that. Not building my 4Runner as a drifter or for rally cross. And I agree on the console. I would prefer a more finished look.
     
  12. Jun 10, 2024 at 5:28 PM
    #12
    Jakobies1086

    Jakobies1086 [OP] New Member

    Joined:
    Jun 7, 2024
    Member:
    #40944
    Messages:
    5
    Gender:
    Male
    First Name:
    Jacob
    Definitely more then one way to get it done thou - if I wan’t so keen on ditching the drum parking brake for a line lock I’d say the 3rd gen console is the way to go. I really think connecting the hand brake in one would be easy work and the remainder of the console swap is similar to the 2nd gen
     
  13. Jun 11, 2024 at 6:16 PM
    #13
    jxdi

    jxdi New Member

    Joined:
    Jun 8, 2024
    Member:
    #40951
    Messages:
    1
    Gender:
    Male
    Vehicle:
    '03 V8 Limited
    Leveling kit, rear Bilstein shocks, 265/70 KO2's, 18" Magnaflow with resonator delete
    awesome write up. looks super clean
     
  14. Jun 13, 2024 at 8:13 PM
    #14
    LOSTR4

    LOSTR4 New Member

    Joined:
    Jun 13, 2024
    Member:
    #41051
    Messages:
    61
    Gender:
    Male
    Vehicle:
    2005 T4R Limited V8 Dorado Gold Pearl
    Just a couple
    Absolutely incredible!
     
  15. Jun 20, 2024 at 12:02 PM
    #15
    RonT4R

    RonT4R New Member

    Joined:
    Mar 24, 2015
    Member:
    #526
    Messages:
    614
    Gender:
    Male
    First Name:
    Ron
    Virginia Beach
    Vehicle:
    2007 4runner SR5 4WD
    Awesome work, btw I have the vertical console surround that came out of a 2WD 4Runner without the 4WD selector switch in my shed if you want it. Just pay for shipping. Also it is painted black. I dyed my interior black because I swapped my seats.
     
    LOSTR4 likes this.
  16. Jun 23, 2024 at 4:04 PM
    #16
    Jakobies1086

    Jakobies1086 [OP] New Member

    Joined:
    Jun 7, 2024
    Member:
    #40944
    Messages:
    5
    Gender:
    Male
    First Name:
    Jacob
    Thanks! It never even crossed my mind that they made these in 2wd and you can get that trim without the cutout for the 4wd knob; as a lifetime resident of the north east salt belt I've never even seen a 2wd 4th gen for sale locally or in person! I do appreciate the offer but I'll keep mine - I am planning on installing a gauge in that spot, specifically thinking the Banks iDash along with a 60mm-52mm adapter

    So I visited a upholstery shop to tackle the shifter boots, and they told me to pound sand. I decided at the expense of it looking good I would tackle it myself instead.
    The transmission shifter boot is a OEM Toyota boot. I cut a slot in the side for the Tcase shifter. The Tcase shifter boot I bought here, on Amazon. I can't sew and I couldn't be bothered to try to learn, so I bought a leather hole puncher from Home Depot and stitched with small black zip ties. It looks decent

    IMG_1858.jpg
    IMG_1857.jpg
    IMG_1856.jpg
    IMG_1860.jpg
    IMG_1859.jpg
     
  17. Jun 23, 2024 at 7:11 PM
    #17
    LOSTR4

    LOSTR4 New Member

    Joined:
    Jun 13, 2024
    Member:
    #41051
    Messages:
    61
    Gender:
    Male
    Vehicle:
    2005 T4R Limited V8 Dorado Gold Pearl
    Just a couple
    Daaaaaang! Looks stellar! I could only imagine the driving of it!!
     
  18. Jun 25, 2024 at 5:06 AM
    #18
    Bluesky 07

    Bluesky 07 Not a New Member

    Joined:
    Jan 26, 2019
    Member:
    #8560
    Messages:
    343
    Gender:
    Male
    First Name:
    Russell
    Northern Georgia
    Vehicle:
    Silver ‘07 Sport V6 4WD @ 258K miles
    “Deep” Satoshi grille | X-REAS delete / TRD Offroad front springs & Bilstein 4600 shocks + FJC rear springs | Weathertech front & rear mats | Tinted front windows | Floor Armor cargo mat | TPMS bypass | LED interior, tag, & reverse lights | BlueSea Systems console USB power ports | Gentex 453 autodim mirror w/Homelink & compass | Kenwood DDX373BT HU + Audiovox backup camera | Fumoto F-103S | Bazooka tube subwoofer | Kenwood speakers & KAC-M1804 amp | Philips H9/9011 headlight bulbs | Rexing V1 Gen3 dash cam | Map light mod | Breather mod | Off-road Nav Setup | Power Stop Z36 brakes | OBD Fusion diagnostics
    I drove a manual Saturn for 6 years and a 5-speed Xterra for 11 more. Really enjoyed it most of the time, though stop and go traffic was tedious.

    I read this thread and heard Darth Vader in my head. "Impressive. Most impressive!" :)
     
    LOSTR4 likes this.

Products Discussed in

To Top