Levee-11's 02 Limited Build Thread (Manual Swap)

[levee-11]

The Preface:

Hello all,
I've been on the forums for years now, ever since I decided I wanted a 4Runner. About 3-4 years ago I picked up my first 4Runner at 16 years old, a 1998 Desert Dune Metallic SR5 V6 4WD from the original owner with 226k. Saying this thing was clean would be an understatement. This vehicle was immaculate. Not a dent, stain, scratch, single bit of fading, nothing. It looked like it rolled straight off the show room floor. I'll attach some pictures of it around the time I picked it up (ignore my plasti-dipped wheels):
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687620386/in/dateposted-public/" title="572804F3-F91C-421A-8E34-2C99268C4562_1_105_c"><img src="https://live.staticflickr.com/65535/52687620386_725002b78f_n.jpg" width="240" height="320" alt="572804F3-F91C-421A-8E34-2C99268C4562_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687619456/in/dateposted-public/" title="5642C576-966C-48F6-892B-B4681DEB7E5B"><img src="https://live.staticflickr.com/65535/52687619456_62b4f7a441.jpg" width="500" height="334" alt="5642C576-966C-48F6-892B-B4681DEB7E5B"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

This was a great first vehicle for me, I loved it, it was mechanically perfect, and took me everywhere I needed to go. Even before I owned it, I knew I was looking to mod it, and take it offroad, and after a little more than a year of ownership, I finally lifted her, and got her looking like this:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687676416/in/dateposted-public/" title="0987F9AB-282D-401D-A073-DF66DD80E0C9_1_105_c"><img src="https://live.staticflickr.com/65535/52687676416_7a87654769_z.jpg" width="640" height="380" alt="0987F9AB-282D-401D-A073-DF66DD80E0C9_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I drove it like this as my daily driver for about a year. Loved every second of it. Took it on a lot of camping trips, and down a lot of trails with friends. Made a lot of memories with it, this thing was truly my baby. I wanted to do more with it, but was always fearful of damaging its cleanliness and didn't really want to dump a ton of money into it. I had a lot of plans but was essentially just very hesitant with following through. Fate however had different plans for it. On July 3rd 2022, on my way to pick up my girlfriend to go shooting up in the mountains, an uninsured, unlicensed woman decided to pull out in front of me on Hwy 169 in WA while I was going 45+, totaling it.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688182033/in/dateposted-public/" title="18F498A2-17E8-4F7C-89F9-34A4F2026CA6_1_105_c"><img src="https://live.staticflickr.com/65535/52688182033_73aeaba04c.jpg" width="375" height="500" alt="18F498A2-17E8-4F7C-89F9-34A4F2026CA6_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688181393/in/dateposted-public/" title="51DBA75A-1BC4-4B74-A9C6-386E2329ED8D_1_105_c"><img src="https://live.staticflickr.com/65535/52688181393_b54f48116e.jpg" width="500" height="375" alt="51DBA75A-1BC4-4B74-A9C6-386E2329ED8D_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I was crushed losing this rig. Death at 246k. The frame had completely buckled above the passenger tire, totaling it. I would have kept and repaired it if I had more room at home. Thankfully I had uninsured motorist insurance, and my insurance company gave me $12,000. I bought the 4Runner back, and got to work looking for one to replace it. I didn't have the room to store a totaled car at my house, so I payed my friend to store it there for a while. After about a week of looking, I found another one owner 4Runner. This one was a 2002 Limited with every single option available save for the supercharger. 206k miles (40k less!). Was it as clean as my old runner? No, but it was pretty damn clean, and had so many more options that my old SR5 did not have. I picked her up for $8500 with all the paperwork, window sticker, and both Field Service Manuals. Here's some pictures from around the time I picked the new rig up:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687182202/in/dateposted-public/" title="3A565ABD-A6ED-444D-A6C9-CFD6E0ECF4B8_1_105_c"><img src="https://live.staticflickr.com/65535/52687182202_3b708c8369_n.jpg" width="240" height="320" alt="3A565ABD-A6ED-444D-A6C9-CFD6E0ECF4B8_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688123645/in/dateposted-public/" title="BD93D5FC-2753-4F26-A315-FC4902A8BF2B_4_5005_c"><img src="https://live.staticflickr.com/65535/52688123645_294210f16f_w.jpg" width="400" height="225" alt="BD93D5FC-2753-4F26-A315-FC4902A8BF2B_4_5005_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

The Build:
I got to work almost immediately. That July was rough for me. The sudden death of a friend, the sudden loss of my dream vehicle, and just after purchasing the new runner, the sudden breakup between my girlfriend and I. I had learned that things can come and go pretty quick, and had regretted all the worry I put into keeping the old runner clean, and not just having more fun with it, because in the end, it got destroyed by someone else's careless actions. I decided I was going to do all the things I wised I had done with the old runner, and I had a good bit of money left over from insurance to get started. I also needed constant distraction from the loss of my girlfriend, so this was great timing for just that.

Lift:
The first thing I did was tear down the old 4Runner. Despite the damage, the lift was completely unscathed, and so were the wheels and tires. I took off the Bilstein 5100 shocks and OME 883/860s I had with my Falken M/T 255/85/16's paired to wheels from a TRD Off-Road Tacoma. Mounted all this up to the new 4Runner and also did ball joints, new tie rods, properly sized new sway bar end links, and pulled the old diff drop off the old runner as well.

Brakes:
I had just done the Tundra upgrade on the old 4Runner prior to the accident. All this was still in good shape, and I pulled everything off, and transferred to the new runner. Bled the brakes, and all was well.

Bumper:
I ordered a 4xInnovations front bumper almost immediately after purchasing the new runner. I opted for no headlight hoops and the shortened bull-bar. I primed the whole thing in my backyard, and shot it with Rust-Oleum Truck Bed liner (I'm writing this about 7-8 months later, and it's held up okay. I wish I did either a flat POR-15 or took it to Line-X). It was looking pretty sharp. I mounted some cheapo Amazon LED pods into my factory fog light harness with removable connections.

Here's how she was looking after the initial transformation:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688150435/in/dateposted-public/" title="3B278E59-3D00-4E0F-93F7-80CE8D731A82_1_201_a"><img src="https://live.staticflickr.com/65535/52688150435_7662895bd4_w.jpg" width="400" height="365" alt="3B278E59-3D00-4E0F-93F7-80CE8D731A82_1_201_a"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I was loving how it was coming along. One problem I ran into was the old 4Runner had really good fitment with the skinny tires, but this new runner had the limited flares, and the tires sat way to far in. I picked up some SpiderTrac 1.25in spacers off Amazon, and that solved that issue.

Headlights:
Always wanted retrofits on my old runner, and decided I was going to get them this time around. The price-tag however was not something I was interested in paying. I decided to build my own. I had done this once before on my friend's 99 Tacoma, so I had some experience. I picked up the kit from BXBuilt for around $350. Painted my housings and shrouds, and was pretty pleased with the outcome. However, I could not for the life of me get them adjusted up high enough. I had no problem with this on my friends Taco, and nothing was visually wrong or loose that could be causing this. I left it as is for the time being, and returned to it later (will cover in this thread).

Here's the rig with the lights and spacers:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688236433/in/dateposted-public/" title="EB6C1303-1056-490C-8814-DA4B7E8E2F1E_1_201_a"><img src="https://live.staticflickr.com/65535/52688236433_70514d5397_w.jpg" width="400" height="394" alt="EB6C1303-1056-490C-8814-DA4B7E8E2F1E_1_201_a"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I picked up a rooftop tent from Facebook Marketplace for $1,000. It's an ARB soft tent that was originally sold by the same dealership this 4Runner was bought at. Prior to this purchase, I always slept in the back of the 4Runner on an air mattress, but being 6'2" this was very crampped, and with the amount of camping trips I take this thing on, I decided it was worth it. I bought the tent using the money I had made selling what was left of the old 4Runner (I got seriously played during that sale, don't ask me about it).

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688180990/in/dateposted-public/" title="8996308E-C5B2-4A5B-A09E-992F4EBE4424_1_105_c"><img src="https://live.staticflickr.com/65535/52688180990_3d1c81b67e_w.jpg" width="372" height="400" alt="8996308E-C5B2-4A5B-A09E-992F4EBE4424_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688179775/in/dateposted-public/" title="08A501F0-86F6-4AFE-A3F5-C0FFA4397D66_1_105_c"><img src="https://live.staticflickr.com/65535/52688179775_982f6efa12_w.jpg" width="400" height="300" alt="08A501F0-86F6-4AFE-A3F5-C0FFA4397D66_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Visually, this is for the most part how she sits today (2/13/23), but far from all the work that went into it. Buckle in, this is where the work starts piling up.
-
-
-
-
-
-
-
-
-

 

[levee-11]

The Repairs:

I had her about where I wanted her for the time being. There were a couple things to address however that were not mod related. A day or two after purchasing, I noticed a rust spot forming on the A pillar next to the windshield caused by a poor windshield install. This was unfortunate as it was going to probably be a costly fix, and something I could have used as leverage to lower the price a little had I noticed it.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688061579/in/dateposted-public/" title="F25269B9-55A8-4129-BB1E-C904F78F10D0_1_105_c"><img src="https://live.staticflickr.com/65535/52688061579_d55de3d66c_w.jpg" width="300" height="400" alt="F25269B9-55A8-4129-BB1E-C904F78F10D0_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

It wasn't until several months of ownership before I started calling around to body shops and getting quotes for fixing it.

Drumroll please.... $4,000-5,000!!!!

Yeah, no. I'm not paying that much to fix that. Now mind you, I have zero bodywork experience, but I was not about to drop a casual 5k to fix one little spot. I decided I'd take on the work myself. I took off the windshield, and it quickly became apparent that the windshield install was of very very poor quality. Getting the glass off was a PITA, and upon removal I found that not only was that little spot rusty, the whole windshield flange was rusty, and another spot similar to the driver side pillar was forming under the paint on the passenger side. I masked the whole 4Runner off, and got to sanding.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688285883/in/dateposted-public/" title="69606C95-2FB5-461D-BE6C-B59F38089BA0_1_105_c"><img src="https://live.staticflickr.com/65535/52688285883_8a3a107dcf_w.jpg" width="400" height="300" alt="69606C95-2FB5-461D-BE6C-B59F38089BA0_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I got both pillars down to bare metal as well as the flange. I used POR-15 for the whole inside of the flange, and used body filler on the pitting on the pillars.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688061719/in/dateposted-public/" title="2C14989C-8470-49F1-905B-BF8DE10E043B_1_105_c"><img src="https://live.staticflickr.com/65535/52688061719_d5fdaea15b_w.jpg" width="300" height="400" alt="2C14989C-8470-49F1-905B-BF8DE10E043B_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688280153/in/dateposted-public/" title="C73523A0-C34E-4674-AB48-C148088C7FE0_1_105_c"><img src="https://live.staticflickr.com/65535/52688280153_5382ac7c2e_w.jpg" width="300" height="400" alt="C73523A0-C34E-4674-AB48-C148088C7FE0_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I primed both pillars and faded the primer into the existing paint to blend everything together. I was trying to do as quality of a job as I could do for the lowest price I could go. I decided against getting an air gun, and instead opted for super quality aerosol cans. I used a self etching primer, and 2K paint and 2K clear. Primer went down well, and then came time for paint, when I realized I had ordered Millennium Silver Metallic to be mixed, and not Thundercloud Metallic. I called the paint place back, and they said they could not mix the paint code for Thundercloud in an aerosol can, the flake was too advanced for the spray nozzle or something. So now I was stuck. I called around to some other paint places and eventually found a place that said they could mix the 1D2 Thudercloud paint code in an aerosol. Picked it up, sprayed it, and it was perfect. It matched like 90%, the flake was a little strong, but you'd never be able to tell. It all blended pretty well. Clear was the hardest part. I was uncomfortable with how heavy it had to be sprayed, it felt wrong having it so close and spraying so thick, but that's what it took to lay out smooth. Got clear on, let it cure for a week, wet sanded and buffed, and it came out amazing!

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687786576/in/dateposted-public/" title="7ADF1CE3-A3D5-4ACC-AB31-916B1BDFDCAC_1_105_c"><img src="https://live.staticflickr.com/65535/52687786576_d0154e58fa_w.jpg" width="300" height="400" alt="7ADF1CE3-A3D5-4ACC-AB31-916B1BDFDCAC_1_105_c"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688301808/in/dateposted-public/" title="IMG_79BD7D7C06F4-1"><img src="https://live.staticflickr.com/65535/52688301808_180078f65e_w.jpg" width="267" height="400" alt="IMG_79BD7D7C06F4-1"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687290017/in/dateposted-public/" title="IMG_6562"><img src="https://live.staticflickr.com/65535/52687290017_141063e5aa_w.jpg" width="258" height="400" alt="IMG_6562"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I had a new windshield installed with the factory Limited bronze tinting, and that project was all wrapped up. That was a huge undertaking, something completely out of my skill level and knowledge, but it all worked out, and I walked away with more knowledge on body work and want to start tackling bigger projects. Took me maybe 3-4 weeks as I was only working on it on the weekends, and cost about 3-4 hundred dollars. It was a great distraction from the ongoing girlfriend depression haha, who needs therapy when you have rust forming on your A pillars?

---

Radiator:
I had ordered a radiator as soon as I bought the truck, knowing they are a failure point, however never installed it until probably November. I flushed the old green coolant out with distilled water (seriously Greg's Japanese Auto!?!? I'd think a place that specializes in Japanese cars would know to not put green coolant in a Toyota). I replaced the radiator, and refilled it with the proper RED Toyota coolant (Or pink, whatever floats your boat).

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687832366/in/dateposted-public/" title="IMG_6563"><img src="https://live.staticflickr.com/65535/52687832366_db444f6572_w.jpg" width="300" height="400" alt="IMG_6563"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

This brings us to the highlight of this build... The Manual Swap...
-
-
-
-
-
-

 

[levee-11]

The Manual Swap

Refusing to seek professional help for getting over my ex, I decided to fulfill one of my most desirable mods, a manual swap. I had wanted a manual from the very beginning, but just couldn't find one. I've done research over the years on the manual swap, and knew pretty much what I was getting into, but one thing I had never really researched was the manual swap on an 01-02 4Runner, as I had always had a 98. I decided I wanted to retain my cruise control, TRAC/VSC, original computer, reverse lights (duh), and proper fuel trims. I did a lot of research and found a couple member who have done this swap properly, and a couple that kinda hacked it together. I wanted to do the best and cleanest job possible whilst retaining my stock computer, as 03-04 Taco computers were $1,000+. I started ordering the parts. Here's what I ordered in case one of you are doing this:

YotaShop.com:
KIT-1061: Shifter Seat Kit and Shifter Bushing Kit
TRANS PLUG 2: OEM R150F Reverse Sensor Plug
KIT-1051: Clutch master to clutch slave line kit
KIT-1028: Clutch pedal bushing kit

Camelback Toyota Dealership:
90105-10221: Long bolt for starter
90119-12287: 3 of the bell-housing bolts
90311-A0027: Rear Main Seal
90080-11293: The other 3 bell-housing bolts
82998-12440: The wire terminals I used for the reverse connector
90119-08079: Pressure plate bolts
31415-10010: Gasket for master cylinder
90105-10138: Bolts for flywheel

Rock Auto:
CKT040: Aisin OEM Clutch Kit
CRT014: Aisin OEM Slave Cylinder
20723: Pad for brake pedal and clutch pedal
LFW199: LUK Flywheel
EM5908: Transmission Mount
1S5084: Clutch depression switch

Other things you will/may need:
95-04 R150F obviously
Clutch Pedal Assembly (find one with both the depression and release swtich installed)
3 Quarts 75W-90 Gear Oil
Interior rubber shift boot
Interior shifter trim
Interior outer shift boot
RTV, Various nuts/bolts, wiring, loom, zip ties, etc.

I'm not going to go into complete detail, I'll just cover what I feel was important, PM me if you have questions, or DM me on instagram at levi.monsen21

I got after it. Pulled transfer case, drivelines, cross members, auto trans, flexplate, and everything else that needed to come out. Pro Tip, don't bother pulling the starter out, just unbolt it and set it down in the cavity it's in, it's not worth unbolting your brake lines just to find it still will hardly come out, just make sure it's still in that cavity when you put the new trans back in.

I pulled my driver seat out, all the lower dash trim, kick panel, door sill, crotch and defrost duct, center console, and ABS/TRAC computer. Started on the clutch pedal before my transmission even arrived in the mail.

ANOTHER PRO TIP: For your own sanity go to Austin Niemela's YouTube Channel, and send him an email asking for the clutch pedal drill template. That would have saved me so much freaking headache getting the holes for the clutch pedal drilled, but I managed. I cut my brake pedal to make the clutch fit.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687884366/in/dateposted-public/" title="C411D909-FB1B-4452-8912-98DA1E301F84"><img src="https://live.staticflickr.com/65535/52687884366_8f51aa5a79_w.jpg" width="300" height="400" alt="C411D909-FB1B-4452-8912-98DA1E301F84"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687366242/in/dateposted-public/" title="AF259F53-EA41-4CC8-8CE2-ABDD94823E6F"><img src="https://live.staticflickr.com/65535/52687366242_3549116688_w.jpg" width="300" height="400" alt="AF259F53-EA41-4CC8-8CE2-ABDD94823E6F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

My manual trans had finally arrived. I shipped it to my work to save the unloading fee for not having a forklift at home. I found it on Car-Part.com. It was sold by Toyo Parts Only in Hollywood CA for $500 + $250 shipping with 154K on it. Shoutout to those guys, great customer service. Adam helped me over the phone.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688160569/in/dateposted-public/" title="C1500136-981B-48BD-A161-2DC4385E7BA1"><img src="https://live.staticflickr.com/65535/52688160569_bb8f538735_w.jpg" width="300" height="400" alt="C1500136-981B-48BD-A161-2DC4385E7BA1"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Got my flywheel and clutch mounted up. DO YOUR RESEARCH ON CLUTCH ORIENTATION!!! The Aisin clutch has a stamp saying this side is the flywheel side. That is for a 3.0 as they use the same clutch. The 3.4s flip the clutch around. Make sure you read up on that before installing!

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688306530/in/dateposted-public/" title="7935FC9A-7281-4F1B-A838-7B247B45F67C"><img src="https://live.staticflickr.com/65535/52688306530_8f63ef9a76_w.jpg" width="300" height="400" alt="7935FC9A-7281-4F1B-A838-7B247B45F67C"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688306455/in/dateposted-public/" title="00DCC2AD-EEF6-4836-8B2D-E0F5D077EE7E"><img src="https://live.staticflickr.com/65535/52688306455_2f25c6e6cd_w.jpg" width="300" height="400" alt="00DCC2AD-EEF6-4836-8B2D-E0F5D077EE7E"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I replaced rear main seal in the process. Bolted trans up, got transfer case put back in, drivelines in, cross members, trans mount, etc. Mechanically, this is a very easy project if you have some decent mechanical experience. Now comes the wiring...

Like I said, I wanted to keep cruise and VSC/TRAC functioning as normal with the original computer. I also didn't want truck to start without clutch depressed. I wanted this to operate like factory. There is not an abundance out there as far as this wiring info goes. Again PM me or DM me on instagram for more information, but what I did was wire the Park Neutral wires to the clutch depression switch, this way it would only start if clutch was pushed in. Then I wired the drive wire to the release switch, and grounded it to the circuit it was originally grounded to at the trans plug this way, cruise would operate when clutch was released, and would terminate if clutch was pushed in, just like factory. Reverse shares the same power as drive, so I split that circuit to the reverse sensor as well, and grounded that to the reverse wire on the trans plug, which gave me reverse lights when in reverse.

So everything worked as expected? No. Everything but VSC/TRAC worked. Apparently the trans is part of the VSC/TRAC system to my understanding and there is no reasonable way to return this functionality, which is not a big deal, because I actually hate this system, and only wanted it operational for the sake of keeping everything factory. I was going to install a kill switch supplied by [MENTION=120071]mtbtim[/MENTION] anyways, but now will not be doing that. So at the end of the day, cruise works, truck starts with clutch depressed, cruise cancels with clutch depressed, and reverse lights work. I was very happy with my custom harness, and everything was done super meticulously, so it all looks pretty. No pic unfortunately.

I pulled my engine light bulb as I now have 7 permanent trans codes (you can remedy this by installing an 03-04 Taco computer) and also pulled my VSC/TRAC lights. I installed an UltraGauge to monitor fuel trims as I was worried about how the auto computer would be fueling while being on and off the throttle because of the manual shifting. I can also use the gauge to read codes should I ever ACTUALLY get an engine code that isn't trans related.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688183399/in/dateposted-public/" title="88F24049-ACDC-4A78-B873-DAF1ED8D1A2F"><img src="https://live.staticflickr.com/65535/52688183399_8cc7de1c65_w.jpg" width="300" height="400" alt="88F24049-ACDC-4A78-B873-DAF1ED8D1A2F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688330350/in/dateposted-public/" title="E65C0833-57EC-4E1C-BA00-B8833617B73B"><img src="https://live.staticflickr.com/65535/52688330350_7ac6eb2fd3_w.jpg" width="400" height="300" alt="E65C0833-57EC-4E1C-BA00-B8833617B73B"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

To wrap things up on the swap, I ordered a 2WD Automatic Limited 4Runner shifter trim piece that would allow me to cut out the big hole for the manual shifter while keeping the wood grain and avoiding the weird bump from the 4WD Auto trims. I got some edge trimming to go around the hole and then took an Aztec blanket and made a custom shifter boot.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687908446/in/dateposted-public/" title="C1145F05-349E-46F1-B5BC-7446FEA952E3"><img src="https://live.staticflickr.com/65535/52687908446_bc0a16c478_w.jpg" width="300" height="400" alt="C1145F05-349E-46F1-B5BC-7446FEA952E3"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687908356/in/dateposted-public/" title="798E2AA0-2534-4177-94FD-30D39529CD3A"><img src="https://live.staticflickr.com/65535/52687908356_5f408e1506_w.jpg" width="300" height="400" alt="798E2AA0-2534-4177-94FD-30D39529CD3A"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Buttoned everything up, and that's a wrap! Manual swap is done! I drove it halfway across Washington, up to Mt. Rainier twice, downtown Bellevue, and all sorts of other places to test her out, and break in the clutch. After 500 miles I changed out the Valvoline 75W-90 to some Redline MT-90 because everyone here on the forums swears by it. I did this two days ago, and you know what? Screw the MT-90, I hate it. It shifted so much smoother on the cheap ass Valvoline, everyone says it's supposed to be so much smoother on the MT-90, but from my experience that is not the case at all. I'll give it some more time, and report back, but as of now I hate it.

Oh yeah... during the manual swap, I installed a badlands 9000 pound winch in my bumper. Made a bracket to hold the winch controller that bolts to the radiator support, cut the grill to fit it, and made some custom 3D printed pieces to finally fix my headlight adjustment. Oh, and manual swap did not in fact cure the ex girlfriend depression, maybe a solid axle will?

3D printed headlight piece:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687401597/in/dateposted-public/" title="DB3715F0-670D-4FB1-8D48-53C3DD4C18CF"><img src="https://live.staticflickr.com/65535/52687401597_714ab3144e_w.jpg" width="300" height="400" alt="DB3715F0-670D-4FB1-8D48-53C3DD4C18CF"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688195409/in/dateposted-public/" title="B16371D5-7D84-43C7-878B-18B21F01E3E1"><img src="https://live.staticflickr.com/65535/52688195409_3fb4bb25d8_w.jpg" width="400" height="300" alt="B16371D5-7D84-43C7-878B-18B21F01E3E1"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Winch Pics:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688413503/in/dateposted-public/" title="51D47599-1329-486C-80E4-8F2A893F253D"><img src="https://live.staticflickr.com/65535/52688413503_5e27a0bc4f_w.jpg" width="300" height="400" alt="51D47599-1329-486C-80E4-8F2A893F253D"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688194779/in/dateposted-public/" title="418A05C8-53FC-4621-9207-1C344F10D5CE"><img src="https://live.staticflickr.com/65535/52688194779_381ce67ffb_w.jpg" width="300" height="400" alt="418A05C8-53FC-4621-9207-1C344F10D5CE"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688342215/in/dateposted-public/" title="E8DB716E-57FD-4E32-9040-55FDB8F46B1F"><img src="https://live.staticflickr.com/65535/52688342215_4476413848_w.jpg" width="400" height="300" alt="E8DB716E-57FD-4E32-9040-55FDB8F46B1F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

So that's where we are today! I'm excited to finally have a build thread and a place to post my progress. I have a lot of future projects in mind. Really want to do an engine swap. Considering either an LS 5.3, OM603 or OM617, and possibly a 2UZ. Also want to get a rear bumper and sliders. Considering a solid axle swap or supercharger. Also keeping my eyes open for an e-locker.

Now that we're all caught up, I'll start to update on the trails I take her on with my friends, and the million camping trips she's gonna see in the near future. IF anyone has any questions, reach out to me, I'd love to provide any help I can!
-
-
-
-

 

[ben9105]

Great write up and nice looking truck. I'm going to be doing a similar swap to an 02 sport so I might have to pick your brain a bit.

 

[gamefreakgc]

I had given a manual swap a serious thought when my transmission blew. It seems like either time, money or health prevents me from undertaking these big jobs and I revert to just fixing things instead. Great job on the swap! That R150 they sold you looks really clean too, should last a long time.

 

[HiLife]

Thank for sharing your build progress. Glad you could recover from your assault from someone who had no business driving on the road with everyone else, but, it happens. Its 1 out of 3 drivers with no registration and no insurance here where I am.
Big gamble everytime Im on the road. Hoping not to get my rig totaled with one of those that arent financial responsible.
You made the R150 swap look effortlessly easy. Awesome you could do it. Did you find on road drivability a big difference between R150 vs A340f?

 

[JoeT4R]

Dude. Not only is your build thread sick, but your journey along the way. Man, that's going to make for great stories. I promise you that. And to think this is just the beginning. I look forward to seeing all your updates on this thing.

Sent from my SM-S908U using Tapatalk

 

[Dream4runner]

The Manual Swap

Refusing to seek professional help for getting over my ex, I decided to fulfill one of my most desirable mods, a manual swap. I had wanted a manual from the very beginning, but just couldn't find one. I've done research over the years on the manual swap, and knew pretty much what I was getting into, but one thing I had never really researched was the manual swap on an 01-02 4Runner, as I had always had a 98. I decided I wanted to retain my cruise control, TRAC/VSC, original computer, reverse lights (duh), and proper fuel trims. I did a lot of research and found a couple member who have done this swap properly, and a couple that kinda hacked it together. I wanted to do the best and cleanest job possible whilst retaining my stock computer, as 03-04 Taco computers were $1,000+. I started ordering the parts. Here's what I ordered in case one of you are doing this:

YotaShop.com:
KIT-1061: Shifter Seat Kit and Shifter Bushing Kit
TRANS PLUG 2: OEM R150F Reverse Sensor Plug
KIT-1051: Clutch master to clutch slave line kit
KIT-1028: Clutch pedal bushing kit

Camelback Toyota Dealership:
90105-10221: Long bolt for starter
90119-12287: 3 of the bell-housing bolts
90311-A0027: Rear Main Seal
90080-11293: The other 3 bell-housing bolts
82998-12440: The wire terminals I used for the reverse connector
90119-08079: Pressure plate bolts
31415-10010: Gasket for master cylinder
90105-10138: Bolts for flywheel

Rock Auto:
CKT040: Aisin OEM Clutch Kit
CRT014: Aisin OEM Slave Cylinder
20723: Pad for brake pedal and clutch pedal
LFW199: LUK Flywheel
EM5908: Transmission Mount
1S5084: Clutch depression switch

Other things you will/may need:
95-04 R150F obviously
Clutch Pedal Assembly (find one with both the depression and release swtich installed)
3 Quarts 75W-90 Gear Oil
Interior rubber shift boot
Interior shifter trim
Interior outer shift boot
RTV, Various nuts/bolts, wiring, loom, zip ties, etc.

I'm not going to go into complete detail, I'll just cover what I feel was important, PM me if you have questions, or DM me on instagram at levi.monsen21

I got after it. Pulled transfer case, drivelines, cross members, auto trans, flexplate, and everything else that needed to come out. Pro Tip, don't bother pulling the starter out, just unbolt it and set it down in the cavity it's in, it's not worth unbolting your brake lines just to find it still will hardly come out, just make sure it's still in that cavity when you put the new trans back in.

I pulled my driver seat out, all the lower dash trim, kick panel, door sill, crotch and defrost duct, center console, and ABS/TRAC computer. Started on the clutch pedal before my transmission even arrived in the mail.

ANOTHER PRO TIP: For your own sanity go to Austin Niemela's YouTube Channel, and send him an email asking for the clutch pedal drill template. That would have saved me so much freaking headache getting the holes for the clutch pedal drilled, but I managed. I cut my brake pedal to make the clutch fit.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687884366/in/dateposted-public/" title="C411D909-FB1B-4452-8912-98DA1E301F84"><img src="https://live.staticflickr.com/65535/52687884366_8f51aa5a79_w.jpg" width="300" height="400" alt="C411D909-FB1B-4452-8912-98DA1E301F84"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687366242/in/dateposted-public/" title="AF259F53-EA41-4CC8-8CE2-ABDD94823E6F"><img src="https://live.staticflickr.com/65535/52687366242_3549116688_w.jpg" width="300" height="400" alt="AF259F53-EA41-4CC8-8CE2-ABDD94823E6F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

My manual trans had finally arrived. I shipped it to my work to save the unloading fee for not having a forklift at home. I found it on Car-Part.com. It was sold by Toyo Parts Only in Hollywood CA for $500 + $250 shipping with 154K on it. Shoutout to those guys, great customer service. Adam helped me over the phone.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688160569/in/dateposted-public/" title="C1500136-981B-48BD-A161-2DC4385E7BA1"><img src="https://live.staticflickr.com/65535/52688160569_bb8f538735_w.jpg" width="300" height="400" alt="C1500136-981B-48BD-A161-2DC4385E7BA1"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Got my flywheel and clutch mounted up. DO YOUR RESEARCH ON CLUTCH ORIENTATION!!! The Aisin clutch has a stamp saying this side is the flywheel side. That is for a 3.0 as they use the same clutch. The 3.4s flip the clutch around. Make sure you read up on that before installing!

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688306530/in/dateposted-public/" title="7935FC9A-7281-4F1B-A838-7B247B45F67C"><img src="https://live.staticflickr.com/65535/52688306530_8f63ef9a76_w.jpg" width="300" height="400" alt="7935FC9A-7281-4F1B-A838-7B247B45F67C"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688306455/in/dateposted-public/" title="00DCC2AD-EEF6-4836-8B2D-E0F5D077EE7E"><img src="https://live.staticflickr.com/65535/52688306455_2f25c6e6cd_w.jpg" width="300" height="400" alt="00DCC2AD-EEF6-4836-8B2D-E0F5D077EE7E"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

I replaced rear main seal in the process. Bolted trans up, got transfer case put back in, drivelines in, cross members, trans mount, etc. Mechanically, this is a very easy project if you have some decent mechanical experience. Now comes the wiring...

Like I said, I wanted to keep cruise and VSC/TRAC functioning as normal with the original computer. I also didn't want truck to start without clutch depressed. I wanted this to operate like factory. There is not an abundance out there as far as this wiring info goes. Again PM me or DM me on instagram for more information, but what I did was wire the Park Neutral wires to the clutch depression switch, this way it would only start if clutch was pushed in. Then I wired the drive wire to the release switch, and grounded it to the circuit it was originally grounded to at the trans plug this way, cruise would operate when clutch was released, and would terminate if clutch was pushed in, just like factory. Reverse shares the same power as drive, so I split that circuit to the reverse sensor as well, and grounded that to the reverse wire on the trans plug, which gave me reverse lights when in reverse.

So everything worked as expected? No. Everything but VSC/TRAC worked. Apparently the trans is part of the VSC/TRAC system to my understanding and there is no reasonable way to return this functionality, which is not a big deal, because I actually hate this system, and only wanted it operational for the sake of keeping everything factory. I was going to install a kill switch supplied by [MENTION=120071]mtbtim[/MENTION] anyways, but now will not be doing that. So at the end of the day, cruise works, truck starts with clutch depressed, cruise cancels with clutch depressed, and reverse lights work. I was very happy with my custom harness, and everything was done super meticulously, so it all looks pretty. No pic unfortunately.

I pulled my engine light bulb as I now have 7 permanent trans codes (you can remedy this by installing an 03-04 Taco computer) and also pulled my VSC/TRAC lights. I installed an UltraGauge to monitor fuel trims as I was worried about how the auto computer would be fueling while being on and off the throttle because of the manual shifting. I can also use the gauge to read codes should I ever ACTUALLY get an engine code that isn't trans related.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688183399/in/dateposted-public/" title="88F24049-ACDC-4A78-B873-DAF1ED8D1A2F"><img src="https://live.staticflickr.com/65535/52688183399_8cc7de1c65_w.jpg" width="300" height="400" alt="88F24049-ACDC-4A78-B873-DAF1ED8D1A2F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688330350/in/dateposted-public/" title="E65C0833-57EC-4E1C-BA00-B8833617B73B"><img src="https://live.staticflickr.com/65535/52688330350_7ac6eb2fd3_w.jpg" width="400" height="300" alt="E65C0833-57EC-4E1C-BA00-B8833617B73B"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

To wrap things up on the swap, I ordered a 2WD Automatic Limited 4Runner shifter trim piece that would allow me to cut out the big hole for the manual shifter while keeping the wood grain and avoiding the weird bump from the 4WD Auto trims. I got some edge trimming to go around the hole and then took an Aztec blanket and made a custom shifter boot.

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687908446/in/dateposted-public/" title="C1145F05-349E-46F1-B5BC-7446FEA952E3"><img src="https://live.staticflickr.com/65535/52687908446_bc0a16c478_w.jpg" width="300" height="400" alt="C1145F05-349E-46F1-B5BC-7446FEA952E3"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687908356/in/dateposted-public/" title="798E2AA0-2534-4177-94FD-30D39529CD3A"><img src="https://live.staticflickr.com/65535/52687908356_5f408e1506_w.jpg" width="300" height="400" alt="798E2AA0-2534-4177-94FD-30D39529CD3A"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Buttoned everything up, and that's a wrap! Manual swap is done! I drove it halfway across Washington, up to Mt. Rainier twice, downtown Bellevue, and all sorts of other places to test her out, and break in the clutch. After 500 miles I changed out the Valvoline 75W-90 to some Redline MT-90 because everyone here on the forums swears by it. I did this two days ago, and you know what? Screw the MT-90, I hate it. It shifted so much smoother on the cheap ass Valvoline, everyone says it's supposed to be so much smoother on the MT-90, but from my experience that is not the case at all. I'll give it some more time, and report back, but as of now I hate it.

Oh yeah... during the manual swap, I installed a badlands 9000 pound winch in my bumper. Made a bracket to hold the winch controller that bolts to the radiator support, cut the grill to fit it, and made some custom 3D printed pieces to finally fix my headlight adjustment. Oh, and manual swap did not in fact cure the ex girlfriend depression, maybe a solid axle will?

3D printed headlight piece:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52687401597/in/dateposted-public/" title="DB3715F0-670D-4FB1-8D48-53C3DD4C18CF"><img src="https://live.staticflickr.com/65535/52687401597_714ab3144e_w.jpg" width="300" height="400" alt="DB3715F0-670D-4FB1-8D48-53C3DD4C18CF"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688195409/in/dateposted-public/" title="B16371D5-7D84-43C7-878B-18B21F01E3E1"><img src="https://live.staticflickr.com/65535/52688195409_3fb4bb25d8_w.jpg" width="400" height="300" alt="B16371D5-7D84-43C7-878B-18B21F01E3E1"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Winch Pics:
<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688413503/in/dateposted-public/" title="51D47599-1329-486C-80E4-8F2A893F253D"><img src="https://live.staticflickr.com/65535/52688413503_5e27a0bc4f_w.jpg" width="300" height="400" alt="51D47599-1329-486C-80E4-8F2A893F253D"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688194779/in/dateposted-public/" title="418A05C8-53FC-4621-9207-1C344F10D5CE"><img src="https://live.staticflickr.com/65535/52688194779_381ce67ffb_w.jpg" width="300" height="400" alt="418A05C8-53FC-4621-9207-1C344F10D5CE"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52688342215/in/dateposted-public/" title="E8DB716E-57FD-4E32-9040-55FDB8F46B1F"><img src="https://live.staticflickr.com/65535/52688342215_4476413848_w.jpg" width="400" height="300" alt="E8DB716E-57FD-4E32-9040-55FDB8F46B1F"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

So that's where we are today! I'm excited to finally have a build thread and a place to post my progress. I have a lot of future projects in mind. Really want to do an engine swap. Considering either an LS 5.3, OM603 or OM617, and possibly a 2UZ. Also want to get a rear bumper and sliders. Considering a solid axle swap or supercharger. Also keeping my eyes open for an e-locker.

Now that we're all caught up, I'll start to update on the trails I take her on with my friends, and the million camping trips she's gonna see in the near future. IF anyone has any questions, reach out to me, I'd love to provide any help I can!
-
-
-
-

I really like to swap to manual even though my auto on the 2000 limited works like new. Problem is I can’t do it myself for various reasons but I wonder if anyone here can direct me to a trusted and reputable shop where I can get the job done with confidence and at reasonable cost. I know there’s a lot involved and best is to find a same year or so runner or Tacoma donor which I have no problem doing.
Any idea anyone? Appreciate this in advance

 

[levee-11]

Thank for sharing your build progress. Glad you could recover from your assault from someone who had no business driving on the road with everyone else, but, it happens. Its 1 out of 3 drivers with no registration and no insurance here where I am.
Big gamble everytime Im on the road. Hoping not to get my rig totaled with one of those that arent financial responsible.
You made the R150 swap look effortlessly easy. Awesome you could do it. Did you find on road drivability a big difference between R150 vs A340f?

Thanks man! Yeah, to this day, my insurance is still trying to pursue getting some money out of her. She was let go from the scene by the police with nothing but like a little $200 fine. Don't get me started about how I feel about these people, or the way they are dealt with.

As far as manual swap, there's no drivability difference other than the obvious fact that it's a manual and that can make certain situations just a little more difficult. I did notice my old trans would have my engine at like 2.1k rpms at 70 in fourth gear, but the manual has it at like 2.8k at 70 in fifth which i find a little odd that the gear ratio is different. Other than that, no issues with it at all!

Update:
Took the 4Runner up with my group of buddies last weekend to Mt. Rainier for a little camping:

<a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52722488156/in/dateposted-public/" title="IMG_6683"><img src="https://live.staticflickr.com/65535/52722488156_fdcfb0609c_w.jpg" width="300" height="400" alt="IMG_6683"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script><a data-flickr-embed="true" href="https://www.flickr.com/photos/197757403@N08/52722488176/in/dateposted-public/" title="IMG_6655"><img src="https://live.staticflickr.com/65535/52722488176_457c24a542_w.jpg" width="300" height="400" alt="IMG_6655"></a><script async src="//embedr.flickr.com/assets/client-code.js" charset="utf-8"></script>

Absolutely love the roof tent. Being the soft tent kind, it's a little bit of a pain in the ass to set up and put away compared to a hardshell wedge type, but still so worth it with how well I fit, and how much room is in there.

Also changed the Redline MT-90 back to some conventional Valvoline 75w-90. I tried to give the MT-90 a chance, but it sucked so bad...

Ordered some new parts for the 4Runner, should be here soon. Once I have them on and all set I'll show you guys. Thanks for all the responses on my initial post!

 

[phattyduck]

I did notice my old trans would have my engine at like 2.1k rpms at 70 in fourth gear, but the manual has it at like 2.8k at 70 in fifth which i find a little odd that the gear ratio is different.

At that time, Toyota ran top gear RPMs higher in all of their MT vehicles. Camry V6 auto vs. mt were the same way. Basically 2k-2.2k at highway speeds on the auto and just under 3k for the manual. My (4-cylinder) Camry is 3k RPM at freeway speeds, but that's with a turbo and geared short to be 'sporty' with the motor swap.

-Charlie