Manual to auto swap

Blizzard · 07-25-2008, 11:44 AM

Hello,

Just wanted to show you how we're working in the manual to auto swap.

Why auto? Because as my truck is not EFI I need a standalone computer to control the tranny, so I can configure it to my taste. Because if a 3.0 intercooled turbo diesel is cool, an auto 3.0 intercooled turbo diesel is way cooler!

I'm going to use a SupraStick computer to control the tranny, being able to choose between two automatic modes and a full manual mode with overrev protection.

As I've a Momo steering wheel I'm going to buy a thing like this to have shift controls in the steering wheel:

Also I can put a simple 16x4 display and monitor the speed, the RPM, the TPS and gear engaged.

This is an A343F auto tranny out from a 3.0TD Hilux Surf. Also got the TC, flywheel, bellhousing and shifter.

The A343F it's almost identical to the A340F, I think the only difference is some gear ratio.
Nice thing of being a "F" series is that the tranny isn't a part of the tranny like in the A340H's you've in the States. This means it has a standard V6 pattern so I can put my chain driven T-Case or put duals in a future.

Have you seen the fancy customized short sleeve coveralls my friend has?

The T-Case it's almost identical to the chain driven ones on the R150F manual trucks, but we're going to use mine instead of this because this is an electric actuated one and the motor would interfer with my parking disc brake. Also less electrics, less problems. Nice thing of those electric transfers is that you can have a "dual shifter" with only a switch.

This is the shifter linkage

T-Case actuator. Only has one rail for controlling the ratio.

Bellhousing

Parts we are not using. The throttle cable and cooler tubes. I'll use a big cooler in front of the radiator and will be blocking the throttle cable in WOT position to have the tranny pressure always high. Will make a little noise when idling and will require a bit more brake pedal in the red lights but will make quickier shifts (Cooler ATF, more reliable tranny).

T-Case and tranny coupling

The electric tranny we're discarting

Pulling the tranny pan you find the filter

Pulling the filter you can see the valve body and the solenoids. Two for the shifts and one for the TC lock-up.

Lots of bolts!

This is the valve controlling the tranny pressure IIRC.

Those are the shifting accumulators. From left to right the 1-2, the 2-3 and the 3-O/D.

In the 1-2 and 2-3 accumulators we're going to do a mod the Supra guys developed. It consists of shimming the little springs so more pressure is achieved. This makes the shifting quickier and harder. The Supra guys had excelent results with this mod and they've engines developing +450HP...

Here is where the shim goes

This accumulator will remain stock as the shifts you want quicker and more used are the 1-2 and 2-3.

Valve body detail.

This is the shifter rail

Hope you like it.

I'm going to order the tranny cooler and the SupraStick.

David

ROCK HOUND · 07-25-2008, 12:11 PM

i probably shouldnt admit this, but i dont understand about 90% of that, but i will spend the rest of my life trying too.

Good luck

scuba · 07-25-2008, 12:26 PM

Well congrats on being one of the few on here that actually understands alot about trannys

4RunnerKid · 07-25-2008, 03:58 PM

glad to see you finally started this David, looks like a pretty intense project... the lazy people like me go the other way.

best of luck with the swap, i'll definitely be checking back.

Blizzard · 07-26-2008, 01:18 AM

Thanks

ROCK HOUND, scuba, I was a complete auto tranny ignorant since two weeks ago... But I searched and read a lot here on YT, Google and also on HowStuffWorks.com

In that last site they've a very very nice explanations about the TC and trannys.

Tonight I ordered the SupraStick and the remote mount TPS.

David

4RunnerKid · 08-11-2008, 11:27 AM

any updates on this David?

Blizzard · 08-11-2008, 11:55 AM

We're waiting for some seals and gaskets from Toyota. As we are there it's better to change them. Also the truck was at the body shop for the hood scoop so we couldn't work on it.

I received the universal mount TPS and expect to receive the SupraStick soon.

As soon as I've more updates I'll post them.

David

Blizzard · 09-07-2008, 02:42 AM

Time for an update hehe

Taking off the drive shafts

T-Case parking brake

The R-150F goes to the ground

Clutch showing up

I really want to see how is the clutch disc after 14 years and 199000mi...

We ordered the rear main seal and later we saw it was needed hehehe

Soon I'll have more pics.

David

Blizzard · 09-07-2008, 02:47 AM

I forgot I had some misc pics too...

This is the SupraStick as we received it from Latent Solutions:

Seal and gasket kit for the A343F

Universal TPS from Powertrain Control Solutions

David

Blizzard · 09-10-2008, 11:51 AM

Hello,

Some updates, we took out the clutch and replaced the rear main seal.

This is the manual flywheel:

And my beloved stock clutch... 14 years of use and 199k miles and still the same that the factory put in my 4Runner. It's still at 3/4 life.

The rear main seal that leaked

This weekend I'm travelling where my truck is for two weeks so I'll have more updates.

David

David

Blizzard · 09-11-2008, 03:25 AM

Seems that here this is not a very interesting swap but... I've new pics so here they are.

The mechanical T-Case that came with my manual R150F bolts with no problems to the A343F tranny.

No problems either with the two rods that came from the T-Case, one for the traction and another for the ratio. The electric T-Case of the A343F only have one for the ratio.

We've only to clean the boxes and shim the accumulators.

Electric T-Case (Left), that came from the A343F and the mechanical T-Case (Right) that came with the R150F.

This coupler has different sizes in each T-Case but it doesn't suppose any problem because the clearance is perfect and it's the same spline count.
This is the coupler from the electric T-Case

Coupler interior

Mech T-Case coupler

A343F coupling with the T-Case

Cheers,

David

Blizzard · 09-30-2008, 10:08 AM

Time for updates hehe

Hello,

We cleaned a little the tranny

Begin cleaning...

During

Looks like something's missing... :scratchch :scratchch :scratchch

This is one of the shims machined in alu to increase the pressure in the shifting accumulators. They're being installed in the 1-2 accumulator and 2-3 one. They add 6mm to the springs.

Changed all the case seals except for the gears ones. Clutch discs were in excellent condition so no need for rebuilding the whole tranny. That thing in the splines is for the speed sensor of the tranny

Where the T-Case stick bolts

The filter

Valve body

The solenoids. The nearer is for the TC lockup and the other two are for the shifts

Cleaned the oil pan. It has some magnets to collect small metal shavings

Valve body

Cleaned the oil pan joint

Bellhousing

Tranny interior

Accumulators. Ones being shimmed are the right ones

Opened the valve body to change the gaskets. You've to be careful with the metal balls and a small spring

All cleaned and ready to assemble

A bit of bling

Assembly ready to lift

Clanged the rear main seal (The crackshaft one)

Auto flywheel before cleaning

Lifting the tranny

Had to enlarge the floor hole 8cm

Cleaned the T-Case stick

Fabbed a new crossmember to support the tranny

Gusseted supports

Parking brake

Then noticed the front driveshaft would hit, so a plasma touch and a piece of tube solved it

Cut some rigid diesel pipes that interfered with the parking brake disc and swapped with rubber ones

When I started the truck I was very dissapointed, the wheels didn't move. We checked the pressure of the tranny and was 0, so we've to spend some time in taking it off again. Removed the oil pump and found this

Luckily that part it's like 45$ from Toyota and we had it in three days

I replaced the gear, put the tranny up and filled with ATF and voila! It works perfect.

Then begin with the electronics... Fabbed a support for the TPS in the injection pump (My truck it's a 1KZ-T without ECU)

Universal TPS

Mounted it on the firewall behind the intercooler

TPS mounted

Then begin with the osciloscope searching for the RPM signal...

Found it but it was only 0.5V idling and 1.5V accelerating and had quite noise. So we desoldered a condenser and two transistors from an old PC power supply and made a filter/amplifier for the RPM signal

And made testing paddle buttons for sequential modes

Put the truck in the dyno to make it run

As I'm testing no wires are still well situated hahaha

Tested the truck on the dyno and all was fine in sequential mode. I took a notepad and wrote the speeds at 2000 and 3000rpm in each gear so I could calculate certain speeds at X rpm in each gear. Then made a big calc sheet with the speeds at 1500 and at 3700rpm. Used the 1500rpm speed for the 5% TPS value and the 3700rpm for the 100% (WOT) value, then I searched the "intermediate" values for each 5% more throttle.

This was for upshifts and was quite intuitive. The problem was the downshifts. Took the Supra downshift table and used the same proportions applied on my truck (It's a diesel so I cannot (And don't need to) take it to the 6000rpm).

Tested it on the dyno and it was fine. Accelerating lightly the truck upshifts quick and at low rpm, then floor it and I'll downshift and let the engine scream hehe

In the dyno rollers it made 180kph (112mph) and stopped because the needle don't read more. Also made 0-60 on 5.22 seconds.
I know in the street it's not the same (You don't have aerodinamic resistance in the dyno and so) but since the intercooler install the truck it's super fast and powerful.

Went to the street to test it and it was very nice, now I've a shift table to start to work on. I can easily change the shifting points at any time.

Hope you like it

David

***waskillywabbit*** · 09-30-2008, 10:17 AM

That is some cool stuff. Wish I had the time for such things.

yotasavg · 09-30-2008, 10:25 AM

wow david.....speachless here.......great work!!! i'm soooo impressed with everything you post. i feel like you have become a very skilled mechanic/fabricator.

Blizzard · 09-30-2008, 12:40 PM

Thanks, I feel that too... If only I had all those nice tools nearer...

David

07-25-2008, 11:44 AM	#1 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Manual to auto swap Hello, Just wanted to show you how we're working in the manual to auto swap. Why auto? Because as my truck is not EFI I need a standalone computer to control the tranny, so I can configure it to my taste. Because if a 3.0 intercooled turbo diesel is cool, an auto 3.0 intercooled turbo diesel is way cooler! I'm going to use a SupraStick computer to control the tranny, being able to choose between two automatic modes and a full manual mode with overrev protection. As I've a Momo steering wheel I'm going to buy a thing like this to have shift controls in the steering wheel: Also I can put a simple 16x4 display and monitor the speed, the RPM, the TPS and gear engaged. This is an A343F auto tranny out from a 3.0TD Hilux Surf. Also got the TC, flywheel, bellhousing and shifter. The A343F it's almost identical to the A340F, I think the only difference is some gear ratio. Nice thing of being a "F" series is that the tranny isn't a part of the tranny like in the A340H's you've in the States. This means it has a standard V6 pattern so I can put my chain driven T-Case or put duals in a future. Have you seen the fancy customized short sleeve coveralls my friend has? The T-Case it's almost identical to the chain driven ones on the R150F manual trucks, but we're going to use mine instead of this because this is an electric actuated one and the motor would interfer with my parking disc brake. Also less electrics, less problems. Nice thing of those electric transfers is that you can have a "dual shifter" with only a switch. This is the shifter linkage T-Case actuator. Only has one rail for controlling the ratio. Bellhousing Parts we are not using. The throttle cable and cooler tubes. I'll use a big cooler in front of the radiator and will be blocking the throttle cable in WOT position to have the tranny pressure always high. Will make a little noise when idling and will require a bit more brake pedal in the red lights but will make quickier shifts (Cooler ATF, more reliable tranny). T-Case and tranny coupling The electric tranny we're discarting Pulling the tranny pan you find the filter Pulling the filter you can see the valve body and the solenoids. Two for the shifts and one for the TC lock-up. Lots of bolts! This is the valve controlling the tranny pressure IIRC. Those are the shifting accumulators. From left to right the 1-2, the 2-3 and the 3-O/D. In the 1-2 and 2-3 accumulators we're going to do a mod the Supra guys developed. It consists of shimming the little springs so more pressure is achieved. This makes the shifting quickier and harder. The Supra guys had excelent results with this mod and they've engines developing +450HP... Here is where the shim goes This accumulator will remain stock as the shifts you want quicker and more used are the 1-2 and 2-3. Valve body detail. This is the shifter rail Hope you like it. I'm going to order the tranny cooler and the SupraStick. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

07-25-2008, 03:58 PM	#4 (permalink)
4RunnerKid Registered User Join Date: Aug 2004 Location: Sac + SLO, CA Posts: 1,003	glad to see you finally started this David, looks like a pretty intense project... the lazy people like me go the other way. best of luck with the swap, i'll definitely be checking back. __________________ -Mikey- 1993 4Runner ~ TG 5" HD/RUF front \| All Pro ~4" rear \| 37" Krawlers \| bomb-proof front housing \| Marlin UM06s \| 12" Fox 2.0s \| Aussie front \| Lock-Right rear \| 5-speed swap \| TG 4.7s \| 5.29s \| bumpers \| sliders \| t-case skid \| K&N intake \| Flowmaster 40 \| Optima red top \| clear lenses \| PIAA 1400s \| KCs \| LED rock lights \| Midland CB \| Firestik 4' antenna \| PIAA superwhites \| stereo Polygoats 4-Wheel Drive Club -> check it yo

07-26-2008, 01:18 AM	#5 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Thanks ROCK HOUND, scuba, I was a complete auto tranny ignorant since two weeks ago... But I searched and read a lot here on YT, Google and also on HowStuffWorks.com In that last site they've a very very nice explanations about the TC and trannys. Tonight I ordered the SupraStick and the remote mount TPS. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

08-11-2008, 11:27 AM	#6 (permalink)
4RunnerKid Registered User Join Date: Aug 2004 Location: Sac + SLO, CA Posts: 1,003	any updates on this David? __________________ -Mikey- 1993 4Runner ~ TG 5" HD/RUF front \| All Pro ~4" rear \| 37" Krawlers \| bomb-proof front housing \| Marlin UM06s \| 12" Fox 2.0s \| Aussie front \| Lock-Right rear \| 5-speed swap \| TG 4.7s \| 5.29s \| bumpers \| sliders \| t-case skid \| K&N intake \| Flowmaster 40 \| Optima red top \| clear lenses \| PIAA 1400s \| KCs \| LED rock lights \| Midland CB \| Firestik 4' antenna \| PIAA superwhites \| stereo Polygoats 4-Wheel Drive Club -> check it yo

08-11-2008, 11:55 AM	#7 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	We're waiting for some seals and gaskets from Toyota. As we are there it's better to change them. Also the truck was at the body shop for the hood scoop so we couldn't work on it. I received the universal mount TPS and expect to receive the SupraStick soon. As soon as I've more updates I'll post them. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

09-07-2008, 02:42 AM	#8 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Time for an update hehe Taking off the drive shafts T-Case parking brake The R-150F goes to the ground Clutch showing up I really want to see how is the clutch disc after 14 years and 199000mi... We ordered the rear main seal and later we saw it was needed hehehe Soon I'll have more pics. David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write... Last edited by Blizzard : 09-07-2008 at 02:44 AM.

09-07-2008, 02:47 AM	#9 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	I forgot I had some misc pics too... This is the SupraStick as we received it from Latent Solutions: Seal and gasket kit for the A343F Universal TPS from Powertrain Control Solutions David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

09-10-2008, 11:51 AM	#10 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Hello, Some updates, we took out the clutch and replaced the rear main seal. This is the manual flywheel: And my beloved stock clutch... 14 years of use and 199k miles and still the same that the factory put in my 4Runner. It's still at 3/4 life. The rear main seal that leaked This weekend I'm travelling where my truck is for two weeks so I'll have more updates. David David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

09-11-2008, 03:25 AM	#11 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Seems that here this is not a very interesting swap but... I've new pics so here they are. The mechanical T-Case that came with my manual R150F bolts with no problems to the A343F tranny. No problems either with the two rods that came from the T-Case, one for the traction and another for the ratio. The electric T-Case of the A343F only have one for the ratio. We've only to clean the boxes and shim the accumulators. Electric T-Case (Left), that came from the A343F and the mechanical T-Case (Right) that came with the R150F. This coupler has different sizes in each T-Case but it doesn't suppose any problem because the clearance is perfect and it's the same spline count. This is the coupler from the electric T-Case Coupler interior Mech T-Case coupler A343F coupling with the T-Case Cheers, David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

09-30-2008, 10:08 AM	#12 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Time for updates hehe Hello, We cleaned a little the tranny Begin cleaning... During Looks like something's missing... :scratchch :scratchch :scratchch This is one of the shims machined in alu to increase the pressure in the shifting accumulators. They're being installed in the 1-2 accumulator and 2-3 one. They add 6mm to the springs. Changed all the case seals except for the gears ones. Clutch discs were in excellent condition so no need for rebuilding the whole tranny. That thing in the splines is for the speed sensor of the tranny Where the T-Case stick bolts The filter Valve body The solenoids. The nearer is for the TC lockup and the other two are for the shifts Cleaned the oil pan. It has some magnets to collect small metal shavings Valve body Cleaned the oil pan joint Bellhousing Tranny interior Accumulators. Ones being shimmed are the right ones Opened the valve body to change the gaskets. You've to be careful with the metal balls and a small spring All cleaned and ready to assemble A bit of bling Assembly ready to lift Clanged the rear main seal (The crackshaft one) Auto flywheel before cleaning Lifting the tranny Had to enlarge the floor hole 8cm Cleaned the T-Case stick Fabbed a new crossmember to support the tranny Gusseted supports Parking brake Then noticed the front driveshaft would hit, so a plasma touch and a piece of tube solved it Cut some rigid diesel pipes that interfered with the parking brake disc and swapped with rubber ones When I started the truck I was very dissapointed, the wheels didn't move. We checked the pressure of the tranny and was 0, so we've to spend some time in taking it off again. Removed the oil pump and found this Luckily that part it's like 45$ from Toyota and we had it in three days I replaced the gear, put the tranny up and filled with ATF and voila! It works perfect. Then begin with the electronics... Fabbed a support for the TPS in the injection pump (My truck it's a 1KZ-T without ECU) Universal TPS Mounted it on the firewall behind the intercooler TPS mounted Then begin with the osciloscope searching for the RPM signal... Found it but it was only 0.5V idling and 1.5V accelerating and had quite noise. So we desoldered a condenser and two transistors from an old PC power supply and made a filter/amplifier for the RPM signal And made testing paddle buttons for sequential modes Put the truck in the dyno to make it run As I'm testing no wires are still well situated hahaha Tested the truck on the dyno and all was fine in sequential mode. I took a notepad and wrote the speeds at 2000 and 3000rpm in each gear so I could calculate certain speeds at X rpm in each gear. Then made a big calc sheet with the speeds at 1500 and at 3700rpm. Used the 1500rpm speed for the 5% TPS value and the 3700rpm for the 100% (WOT) value, then I searched the "intermediate" values for each 5% more throttle. This was for upshifts and was quite intuitive. The problem was the downshifts. Took the Supra downshift table and used the same proportions applied on my truck (It's a diesel so I cannot (And don't need to) take it to the 6000rpm). Tested it on the dyno and it was fine. Accelerating lightly the truck upshifts quick and at low rpm, then floor it and I'll downshift and let the engine scream hehe In the dyno rollers it made 180kph (112mph) and stopped because the needle don't read more. Also made 0-60 on 5.22 seconds. I know in the street it's not the same (You don't have aerodinamic resistance in the dyno and so) but since the intercooler install the truck it's super fast and powerful. Went to the street to test it and it was very nice, now I've a shift table to start to work on. I can easily change the shifting points at any time. Hope you like it David __________________ '94 Toyota 4Runner 3.0 Turbo Diesel Intercooler – Trail-Gear 4'' SAS front, Trail-Gear 5'' rear leaves swap, 35x12.5x15 M/T's and too many things more to write...

09-30-2008, 10:17 AM	#13 (permalink)
*waskillywabbit* Sponsoring Member Join Date: Jul 2003 Location: Tuscaloosa, AL Posts: 11,506	That is some cool stuff. Wish I had the time for such things. __________________ WabFab Off-Road, LLC www.myspace.com/wabfab 6th Annual South East 4Runner Jamboree, May 22-25, 2009 WabFab Off-Road Salvation Army Online Kettle

09-30-2008, 10:25 AM	#14 (permalink)
yotasavg Registered User Join Date: Jan 2007 Location: Chico Republic, NOR*CAL Posts: 1,524	wow david.....speachless here.......great work!!! i'm soooo impressed with everything you post. i feel like you have become a very skilled mechanic/fabricator. __________________ -Andrew 94 4Runner 3.0 Auto. I got mods

09-30-2008, 12:40 PM	#15 (permalink)
Blizzard Registered User Join Date: Jul 2004 Location: Barcelona (Spain) Posts: 873	Thanks, I feel that too... If only I had all those nice tools nearer... David __________________