ARCHIVE: 01-04 Auto-to-Manual Tranny Swap (Junglecode Writeup)

Enola Gaia · Sep 6, 2009

This is an archive thread being established to preserve a major writeup on swapping out an OEM automatic transmission for a 5-speed manual transmission on a 2001 - 2004 Tacoma.

For many years this writeup was the best single source of info on what such a swap involved. Although this writeup specifically addresses such a swap on a Double Cab, it contains a lot of info that applies to other 1995.5 - 2004 models as well.

It was previously available online at the following archive site:

http://www.junglecode.com/toyota/tacoma/Transmission/index.htm

However, this site no longer hosts these writeup materials, and the Web Archive (the Wayback Machine) does not have these webpages archived.

The exact authors of this writeup were unknown, and the writeup did not carry any copyright restrictions.

As such, I shall reconstruct (as best I can ... ) this key writeup for preservation here on CT.

Some editing, reorganization, and rearrangement of the original source material has been done as necessary.

Certain documentation associated with the original writeup (a few photos of the trucks in general; some auxiliary reference materials) have been lost, because they were not included in the JungleCode webpages and / or cannot otherwise be found.

- Enola, 9/06/2009

Enola Gaia · Sep 6, 2009

Toyota Tacoma Transmission Swap

2WD Auto to 4WD 5-speed Manual

Engine: 5VZFE Transmission: R150F

Project: Replace the transmission in a 2003 Toyota Tacoma DoubleCab TRD V6 PreRunner to go from a 2WD automatic (A340E) to a 5-speed manual 4WD (R150F) transmission. The transmission has been installed and is currently being broken in.

Part 1: Preparation (this page)
Part 2: Clutch
Part 3: Clutch Hydraulics
Part 4: Transmission Unit
Part 5: Transmission Installation

To properly prepare for the transmission swap, we carefully inspected 3 different Toyota Tacoma trucks to make sure this swap is possible. Toyota Tacomas are awesome trucks and all three are fine vehicles in their stock form. However, we want a Double Cab truck with 5-speed manual which Toyota does not manufacture.

Our goal is to approach this project as close to OEM as possible. We'll do this by using Toyota parts and tools. In some cases we will use parts from a Toyota OEM supplier like Aisin or NSK. The actual transmission installation will be made at an ASE-certified Lexus repair facility.

2003 Toyota Tacoma TRD Double Cab PreRunner V6 with automatic transmission (A340E). This is the truck that will be converted to 5-speed manual.

2003 Toyota Tacoma TRD Double Cab 4WD V6 with automatic transmission (A340F). We're using this truck to compare the factory 4WD driveline to that of the PreRunner(auto) and ExtraCab(manual.)

2001 Toyota Tacoma TRD ExtraCab 4WD V6 with Manual Transmission (R150F).

Another view of the 2003 Toyota Tacoma TRD Double Cab 4WD with automatic transmission. We are quite impressed with the smooth performance of the automatic transmissions found in Tacoma trucks. However, we still want the 5-speed manual transmission.

Another view of the 2003 Toyota Tacoma TRD Double Cab PreRunner. TRD PreRunners can lock their differentials in 2WD. This greatly increases available traction. We highly recommend locking differentials in Toyota trucks.

TRD Double Cabs have electronically-controlled transmissions (ECT.) When enabled, ECT modifies the shift points in the automatic transmission to rev higher through all the gears.

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Here's a picture of the driver-side firewall in the Double Cab. Note where we will drill 3 holes for the clutch master cylinder and pedal assembly.

(2) Here are the brake and accelerator pedals in the Double Cab. Note where the clutch pedal will be installed. The holes in the firewall go straight from the engine bay to the clutch pedal bracket.

The shifter and center console on the PreRunner Double Cab has two cup holders where the transfer case shifter would normally go. I'm sure we will miss those cup holders when they're gone.

(3) Here's the shifter and center console on the 4WD Double Cab. Compare this console with the one from the 5-speed truck below. Note the position of the transfer case shifter. There are two holes under the console for the transmission and transfer case levers.

(4) Here's another view of the shifter and center console on the 4WD Double Cab. Note the one-touch 4WD button on the transfer case shifter. This button engages 4-hi and automatically locks the front differential. Although this is a convenient feature, especially in rain and snow, we want a manual transfer case for our project to reduce driveline complexity. A manual transfer case will work better with manual front axle hubs.

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

Here are some pictures from the 2001 Toyota Tacoma TRD ExtraCab with V6 engine 4WD and manual transmission. We used this truck as a reference to make sure we hook things up right. Since the 2001 is a 2nd Generation truck like the 2003, many items should just bolt on between the two trucks.

(1) Shifters and Console Detail. We will enlarge the transmission shifter hole under the center console in the DoubleCab to fit the 5-speed stick shifter.

(2) Clutch Start Cancel Switch. On automatic transmission models, the ECT button goes here.

(3) Vehicle Speed Sensor (VSS) is different between 4WD and 2WD. The 4WD version is mounted on the transfer case.

The 5-speed transmission we are using came from a 1996 Toyota Tacoma. We chose that transmission because it has a manual transfer case. The transfer case does not have the one-touch 4WD or Automatic Differential Disconnect (ADD) features that we don't want for our truck. The transmission was readily available and was purchased together with most of the parts necessary for the swap. The bellhousing bolt pattern matches our 5VZFE engine. This will allow us to upgrade the transmission later on to a Marlin Crawler unit.

(4) [Here ...] is a picture of a R150F transmission from a 2001 Tacoma. This isn't our transmission, but a picture we came across for reference. Note the location of the slave cylinder in the front of the bellhousing. Notice how the transmission and transfer case are basically the same across model years:

(5) Here's a picture of our transmission from a 1996 Tacoma. Note the driver side front output flange that differentiates the Tacoma chain-driven transfer cases from gear-driven transfer cases found on earlier Toyota trucks. Marlin also sells an adapter to mate a R150F transmission to a gear-driven transfer case. We may explore this option in the future, depending on our chosen front driveline configuration.

Enola Gaia · Sep 6, 2009

We used the same 1996 Toyota Tacoma to obtain the following necessary parts:

transmission
transfer case
shifters
transmission mount (goes on crossmember)
center console and trim
flywheel
clutch + brake pedal
hard and flexible fluid lines
misc. nuts, bolts + connectors

We're replacing the clutch, pressure plate, pilot and throwout bearing with new parts and we are rebuilding the clutch master and slave cylinders. The driveshafts are different lengths between the Tacomas. 2WD PreRunners have a longer rear driveshaft section between the transfer case and carrier bearing. We may either shorten our driveshaft or locate one from another truck to complete the swap.

Here's a picture of a 2001 V6 5VZFE engine. This isn't our engine, just a picture we came across for reference. Note the flywheel and clutch installed:

We considered using a computer (ECM or ECU) from a 1st Generation Toyota Tacoma to see if we could avoid the 'check engine light' that will inevitably result from removing the automatic transmission. Unfortunately, the ECU connections are not the same on 1995 and 2003 trucks. It may have been possible to splice up the wiring harness to match up with the 1st Gen connectors but we're not going there. We want to stay as close to OEM as possible. Perhaps someone looking to do a similar swap with a 1st Gen Tacoma can use our ECU. We will document our ECU findings and modifications as we make them.

Enola Gaia · Sep 6, 2009

(Part 2)

Toyota Tacoma Clutch

2003 V6 TRD 4WD

Engine: 5VZFE Transmission: R150F

The Toyota Tacoma clutch unit installed with the R150F transmission is a fairly basic and very reliable design that's hasn't changed across the Tacoma model years. Aisin Corporation of Japan manufactures transmissions, clutches and other parts for Toyota. The flywheel unit must come from a Tacoma with a manual transmission as the automatic transmission driveplate will not accept a clutch unit. We will resurface the flywheel before installing the clutch unit. There is an available TRD Heavy Duty clutch kit available but we elected to use the OEM unit instead for the ride quality. The DoubleCab will be used to transport kids and other live cargo so a smoother shift and reliability is desired over racetrack performance so the transmission swap will use OEM-spec parts as needed.

The following paragraphs refer to the attached files, in order of appearance ... Photos of FSM pages in the original writeup have been replaced with the actual FSM PDF files, and this section has been rearranged to accommodate additional FSM documentation.

(1) Here's page CL-15 from the 2003 Toyota Tacoma Factory Service Manual.
Note the order that the parts are installed into the flywheel. The important torque wrench values are visible. Here's a PDF of the same page.

(2) Here's a portion of the 2003 Tacoma FSM illustrating the R150F transmission unit. These transmissions are manufactured by Aisin Corp. of Japan. Note the 2 types of rear driveshafts available on Tacomas with manual transmissions. There are one and two-piece units available. We need the two-piece unit for the Double Cab project.

(3) Here's a PDF from the 2003 FSM illustrating the R150 used in the 2WD V6 Tacomas.

(4) Here's a PDF of the 2003 Tacoma FSM illustrating the R150 / R150F internal components.

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

We are using an Aisin clutch cover and clutch disc.

(1) We are using a kit from eClutchMaster to refurbish the clutch on the DoubleCab. The part number for the entire kit is EC-56035.

(2) Clutch Cover - flywheel side
This part is interchangeable across all Tacomas with the V6 up to 2004.

(3) Clutch Cover - transmission side
We elected to use the Aisin part instead of Toyota since it's a bit less expensive and is manufactured by the same OEM.

(4) Clutch Disc - flywheel side
This part is interchangeable across all Tacomas with the V6 up to 2004.

(5) Clutch Disc - transmission side
Another Aisin OEM part from eClutchMaster.

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Clutch Release Bearing - flywheel side

We are using a Japanese bearing from NSK. Part number 614162 CB-56017.

(2) Clutch Release Bearing - transmission side

We are using a NSK bearing instead of Toyota to try and alleviate some of the clutch noise issues reported by some Tacoma owners using the OEM release bearing. We've heard of Tacoma owners using NSK bearings before in other projects with good results.

(3) The eClutchMaster kit comes with a nice clutch alignment tool that's made in the USA. This is a necessary special service tool (SST) for this project. Also pictured is the only disappointing part in the eClutchMaster kit is the Clutch Pilot Bearing made by HBC ( HENGDA BEARINGS CO., LTD) from China.

The Pilot Bearing will revolve at a redline of 5500 RPM in off-road conditions. We're not taking chances so we will order a Toyota part instead of the HBC bearing. No offense meant to the Chinese bearing company, but we want an OEM installation and I really wish they put in a NSK or other Japanese OEM bearing in the kit.

This bearing is actually available from several manufacturers as a standard part used in many applications. The standard part number for the Clutch Pilot Bearing is 6201RS and is used in all Tacomas with the R150F manual transmission. Here are the specs on the 6201 bearing, the RS suffix means the bearing is sealed with a rubber sleeve.

Dim: ID: 12mm x OD: 32mm x W: 10mm
Desc: Radial Ball Bearing, Chrome Steel, Rubber Sleeve closure

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Here's a shot of the clutch master cylinder in the 2001 Tacoma.

(2) A closer look at the clutch master cylinder showing one of two bolts that protrude from the clutch pedal bracket through the firewall. Click here for more information on the clutch hydraulics.

Enola Gaia · Sep 6, 2009

(Part 3)

Toyota Tacoma Clutch Hydraulics

4WD 5-speed Manual

Engine: 5VZFE Transmission: R150F

This page describes the hydraulic parts that make up the Toyota Tacoma clutch unit installed with the R150F transmission. These parts are required to do a transmission swap from an automatic to a manual transmission.

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Here's a closer look at the 3 driver pedals on the 2001 TRD ExtraCab V6.

(2) The existing brake pedal on the automatic transmission trucks is too large and will need to be replaced with the smaller unit pictured here.

(3) Here's the clutch pedal assembly as seen from the passenger side. Note the master cylinder and fluid reservoir still installed. You can see a detailed diagram by clicking here (PDF file.)

(4) Here's the clutch pedal assembly as seen from the driver side. There's some surface rust on the bracket that we will get sand-blasted and powder-coated.

(5) Here's a diagram of the clutch pedal assembly. The red line shows where the firewall is located. It's very important to drill the holes in the firewall at the correct location so that the clutch pedal is installed correctly relative to the brake and accelerator pedals.

Enola Gaia · Sep 6, 2009

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Here's the clutch master cylinder as seen from the engine bay.

(2) A closer look at the clutch master cylinder as seen from the engine bay. You can see why the three holes in the firewall need to be drilled. Two holes for the mounting bolts and one large hole for the push rod.

(3) Here's a picture of the clutch slave cylinder with the hard and flexible fluid lines still attached. The top-most fluid line is installed by attaching it to the clutch master cylinder in the engine bay.

(4) You can see a detailed diagram of the slave cylinder here (PDF file.)

(5) Here's a close-up of the crossmember mount used for the R150F transmission. This differs from the mount used by the A340 automatic transmissions. ...

Enola Gaia · Sep 6, 2009

(Part 4)

Toyota Tacoma Transmission Unit

4WD 5-speed Manual

Engine: 5VZFE Transmission: R150F
The Toyota Tacoma R150F manual transmission is installed in all 5-speed 4WD Tacomas with the V6 5VZFE engine. This same transmission is used by some 4Runner and T100 trucks that have the V6 engine. It may be possible to perform this same transmission swap with one of those vehicles. This page describes the R150F that we're using in the 5-speed Double-Cab project.

The R150F was also used in 3.0L V6 trucks manufactured before 1995. We've read reports that the input shaft length is different on the pre-Tacoma R150F transmissions.

Other transmissions used on 1995.5 - 2004 V6 Tacomas include:

R150F 5-speed manual 4WD
A340E 4-speed automatic 2WD
A340F 4-speed automatic 4WD

All three transmission units use the same transfer case ...

The following paragraphs refer to the attached photos, in order of appearance ...

(1) Here's a good way to ship a transmission across the United States. The entire pallet with the transmission, transfer case and a box of parts weighed close to 300 pounds. Metal straps were used to attach the transmission to the pallet. Duct tape and rags were used to protect exposed parts.

(2) Here's a closer look at the front output flange on the transfer case. The front drivetrain will not be installed until after the transmission swap is completed.

(3) Note the plug where the vehicle speed sensor (VSS) would be. We'll need to locate a suitable VSS unit before our speedometer will work with the new transmission.

(4) Engine side of the flywheel. Note the gear teeth around the flywheel where the starter motor engages. We'll send this unit out for cleaning and resurfacing.

(5) Transmission side of the flywheel. Note the original clutch cover still installed. We'll leave the old cover on for now so we can put matchmarks on the new cover and the flywheel.

Enola Gaia · Sep 6, 2009

A close-up of the bell housing and input shaft. You can see the original release bearing still installed on the input shaft in front of the clutch fork. note the duct tape wrapped around the input shaft splines to keep it safe in transit. The R150F uses a 21-spline input shaft mated to a 250 mm clutch disc.

Enola Gaia · Sep 6, 2009

(1) Here are the shift levers for the R150F transmission. The shorter one is the transfer case lever. Note the torn rubber boot on the gear selector lever. We will replace that boot before we install the lever.

(2) Here's the center console from the same 1996 Toyota Tacoma where we got the transmission. It has a cup holder that expands to hold two cups. Note that it's Oak color and won't match the Gray interior of the PreRunner. We'll use this item until we can find a suitable gray replacement.

(3) Beneath the center console is the shift lever boot assembly. This is actually two separate parts.

(4) Here's the rubber boot part of the shift lever boot assembly.

(5) Here's the metal retainer part of the shift lever boot assembly. Note the two holes in this part. The larger hole is for the gear selector lever. The smaller hole is for the transfer case selector.

Enola Gaia · Sep 6, 2009

(1) Here's what it looks like with the console removed in the 2001 ExtraCab with manual transmission. Note the rubber boots that keep water and dirt out of the transmission and transfer case.

(2) Another view of the manual transmission with the console removed.

(3) A comparison of two center console covers. The one on the left is from a 2001 Tacoma. The one on the right is from a 1996, which also fits in the newer Tacoma with some minor modifications.

(4) Here's a picture of the rear driveshaft on the ExtraCab. Note the carrier bearing between the two halves of the driveshaft.

(5) A closer look at the driveshaft flange and carrier bearing.

Enola Gaia · Sep 6, 2009

(1) A close-up view of the universal joint on the rear driveshaft that we're using for the swap. Notice that the joint is leaking grease and must be replaced prior to installation. Universal joints are not reusable parts and must be replaced with new units when removed.

(2) The DoubleCab PreRunner driveshaft is 42 inches long from flange to flange. The driveshaft installed with the manual transmission is 11 inches shorter.

(3) A closer look at the transmission mount on the 5-speed 4WD crossmember. The PreRunner mount looks different but mounts on the same crossmember.

(4) Another shot of the transmission mount. Also visible is the small skid plate on the bottom of the transfer case.

Enola Gaia · Sep 6, 2009

(Part 5)

Transmission Installation

DoubleCab PreRunner Automatic to 4WD Manual

A340E to R150F

The following paragraphs refer to the attached photos, in order of appearance ...

(1) DoubleCab trucks don't have the mounting holes for the clutch pedal brackets or master cylinder. They do have the mounting nut under the steering column already, so only 3 holes need to be drilled. Note the pilot hole already drilled for the first and largest hole for the master cylinder.

(2) The drill marks and pilot holes must be made in the cab under the steering column. We made some approximate marks in the engine bay too. Note how the pilot hole for the master cylinder doesn't match the approximate marks.

(3) It's essential to use the master cylinder gasket that comes with the rebuild kit to use as a template when marking the holes. We drilled the big hole using a very sharp 1.25" bi-metal hole saw.

(4) To get a perfect fit for the clutch pedal, we used a very sharp 1/8" drill bit for pilot holes and a 5/16" bit for the mounting holes. Some tape was used to protect the paint while drilling.

(5) A perfect fit takes patience and care. The clutch pedal installation took one whole day to get exactly right.

Enola Gaia · Sep 6, 2009

(1) Getting ready to install the transmission. A hydraulic lift is essential for this job. The type of lift pictured allows full access to the drivetrain.

(2) All the automatic transmission fluid was drained out before the transmission was removed.

(3) Another piece of essential equipment was a pneumatic lifter. Note the Lexus vehicles in the background. It's really nice to have a Lexus repair facility in which to do this job. Tools, parts and reference material were all within reach.

(4) A screw jack supports the automatic transmission before the crossmember was removed.

Enola Gaia · Sep 6, 2009

(1) Here's the automatic transmission unit already removed from the vehicle. Even such a small transmission weighs close to 200 pounds. The A340E 2WD transmission is also used by several Lexus and Toyota cars, trucks and SUV's so perhaps someone will be able to use a nice low mileage unit.

(2) Here's the rear of the engine with the automatic transmission removed. Note the automatic transmission drive plate still installed.

(3) Here's the rear of the engine with the clutch flywheel and pilot bearing installed. Note the nice swirl finish on the resurfaced flywheel. This greatly improves the clutch seating during the initial break-in period.

(4) Here are the manual transmission and transfer case ready to be installed. Note the ExtraCab truck in the background. It's important to have a truck with the same transmission to use as a reference during the installation.

Enola Gaia · Sep 6, 2009

(1) Here are the shifter console holes for the PreRunner. Note the strip of sheet metal that separates the two holes. This strip will need to be removed to make room for the manual transmission shift lever.

(2) An angle grinder was used to cut the sheet metal from under the truck.

(3) Here's the manual transmission installed. We now have the very first Toyota Tacoma DoubleCab with a 5-speed manual transmission.

Enola Gaia · Sep 6, 2009

(Separate section from the original JungleCode writeup)

Toyota Tacoma ECM ECU

1995.5 4x4 V6 5-Speed Manual 89661-04130

Engine: 5VZFE Transmission: R150F

Even though the original authors didn't end up using this ECM in the auto-to-manual conversion, this documentation may be of useful reference to others in the future ...

Here are pictures of the Engine Control Module or ECM (aka ECU). This was taken from a wrecked 1995.5 Toyota Tacoma 4WD with V6 and manual transmission. Also pictured are the connectors with about 6 inches of wires that go to the ECM.

I bought this ECM used but it did not fit my 2003 truck which I am converting from automatic to manual transmission. The connectors are different on the two trucks. The 2003 (2nd Gen. Tacoma) has connectors that have 3 rows of wires. The 1995.5 (1st Gen. Tacoma) has only two rows of wires in the connectors.

This may fit other model years--check your existing ECU part number if it matches 89661-04130.

This type of ECM could be used to convert an existing 2.3 or 3.0L Tacoma to a late-model 3.4L V6 engine. It may also be used to convert a Tacoma with automatic transmission to manual transmission. Be sure to check the connectors on the wiring harness that you plan to use.

Enola Gaia · Sep 6, 2009

Here are the remainder of the ECU / ECM photos from the old JungleCode writeup ...

Enola Gaia · Dec 12, 2009

FYI: Additional info / tips from guys who've done this sort of swap can be found over at TTORA:

http://www.tacomaterritory.com/forum/showthread.php?t=140450

(And, no doubt, in other threads as well ...)

ARCHIVE: 01-04 Auto-to-Manual Tranny Swap (Junglecode Writeup)

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Attachments

Our Vendors

Top Contributors this Month

Recommended Communities