91Toyota

Not sure where to put this, but here it goes


Project: Swapping a manual transmission in for an automatic in a 1986 Toyota pickup with a 22re

I started with this truck because I picked it up for $500 with a 22re and running and somewhat drives.


Then, I picked up this g54 tranny from a 22r (yes, there is difference, but shouldn't matter!) for $100 w/ a fork, but missing shifter and output shaft yoke



Here is the output shaft "yoke" as the dealership calls it. Mine was missing. So $65 more...


Shifter, $5 from the junkyard


Forward shift T-case. If your using a W-series tranny then DON'T get a forward shift transfercase...you will need a top shift. $50


Cross-member, I was told they were different between auto/manuals, but look identical. $15


Flywheel, $15 + $30 for resurfacing so $45


Pedals, you obviously need pedals because you need a clutch $25


Clutch kit, $90


Clutch slave cylinder, $11.50









Okay, thats about all the parts besides a few I am missing.

Now, removing the tranny + transfer case. I thought it would be easiest to drain the fluid first, and to drop everything out at the same time.

First, I removed a couple bolts from the x-member


Then, I took off the shifter



Next, came off front + rear driveshafts



Next, I secured the whole transmission assembly with a transmission jack. That way it would put less stress on the bolts and therefore making it easier to remove.


There goes the hood!


Okay, next, I started removing all the bolts around the tranny. That way I could get it out of there. The hardest bolts were the top 2 on the back of the engine. One took approx. 30 mins. and the other took about 1 and 1/2 minutes. Here is what I used...




Next, grille and tranny cooler.




Next, I removed all the lines or anything attaching to the tranny.
And started pulling it out.






Now its OUT!!!








Money spent so far:
1) Tranny $100
2) T-case $60
3) Flywheel $55
4) Pedals $20
5) x-member $15
6) Tranny seal $4
7) Tranny output $65
8) Clutch $90
9) Clutch master $38
10) Clutch slave $25
11) Shifter $5



NEXT, 5-spd tranny goes in.......











PART 2









Back of the engine


New vs old flywheel


You'll need longer bolts for the flywheel...


Flywheel on


Clutch disc



Pressure plate on...


Tranny + t-case almost about to go in...


Getting closer


Trying to get it to fit



ITS IN!!!!!!!!




Connected drive-lines



Cut hole for shifter


next, installed clutch master cylinder, slave cylinder, lines, and pedals




Next, I jumped two wires near the passenger side wheel well. It needed to be jumped so the computer thinks the truck is in neutral so it will start. No pics...sorry (its got 3 wires and its white, you jump the bigger of the two!)

I hooked up my speedo line



DONE!!!!!

eightnine

Hey man, props on the job so far, my trucks gona be getting the same swap done soon so I'm gona be watching on. Keep it up!

LTrunner

nice...you will love the 5spd over the dogmatic...i did my swap in over a weekend..the auto was out firday night after i got home from work, and the 5spd was in and finished by midday sunday...the swap dosen't really take long so long as you have all the parts...good luck

a4runnerfreak

Looks good so far, 91.

91Toyota

Thanks, now I need some flywheel/pressure plate bolts so I can put it together in the next couple days. I don't feel like waiting a couple weeks on some little bolts from the dealership.

LTrunner

just bring the flywheel to your local hardware store and find the right size bolts...make sure you get grade 8 or stronger...and the bolts are about an inch long...or get the HD ones marlin sells

874runnersr5

looks good so far man, can you use the transfer case off the auto and use it on the manual to run dual tcases? or is there some compatibility issues?

91Toyota

I was told the auto tranny's t-case was a chain driven t-case and the t-case's behind manuals are gear driven...so no. lol

Beaniam

89-95 W-56's are forward shift

874runnersr5

oooh yeah, ah thats a bummer

91Toyota

Swap is done, now I just need to fix rough idle issue

91Toyota

Surprised no one has posted. lol

annoyingrob

Thanks for the writeup

So you re-used the auto driveshafts? Did you have to cut a hole in the firewall for the master cylinder?

91Toyota

No problem.

For the clutch master cylinder, I had first marked the area of where it should be, then I drilled a hole with the biggest drill bit I could. I then used a chisel (sp?) to punch out the hole so it was bigger. It is nice and secure and doesn't move. But I suggest buying a big drill bit, as I didn't have a big drill bit or drill.

And yes, I re-used the driveshafts. They both fit just fine. They seem to be in the exact location.

Are you thinking of the swap?

annoyingrob

Oh, I'm more than thinking about the swap, it's happening as soon as it warms up around here. I'm just trying to make a parts list. Guess I can take driveshafts off of it

I find it interesting that Toyota actually made two different cabs for auto and manual. I see you had to cut out for the shifter, and I noticed that I would also need to cut out for the master cylinder. Does the pedal assembly bolt up, or was there some fab work in that involved?

91Toyota

I think the problem with the shifter hole was that I actually used a tranny and tranfercase off of a 22r, not a 22re. lol. But it works just fine. Maybe required a little more work???

Anyway, the pedal assembly was straight forward. You actually get to keep your gas pedal and believe it or not but the pedal assembly has a mount for the clutch pedal already. All you need is the pedal, the spring, and the bolt that goes through the pedal. And you also need the brake pedal because it is smaller and shaped differently. The mount to the truck is the EXACT same, the pedals are different.

The only thing that I currently do not know about the clutch pedal is whether or not there is another spring attached to the pedal, because it is the softest clutch I've ever felt. But works really well.

I definitely recommend this swap. Having a manual tranny is a whole new world.

TOYOTA 1

good job 91!!!!!!

was there already a spot on the firewall for the master cylinder?

or did you have to fab it in there?

annoyingrob

he said he had to cut it. I already asked that question

TOYOTA 1

oops!

thanks for putin me in check

tonetone

this is an absolutely awesome write up dude. thanks. going to be doing the conversion here shortly myself.