i recently acquired an 89 4Runner with the 22re automatic. I haven't heard too many good things about the auto plus I just prefer the manual anyways. My questions are, does the auto and manual use the same transfer case? And if so, would this make for a straight swap or will I need driveshafts too?
So I guess really, what is entailed in a automatic to manual swap?

 

Do some searching quite a few threads on this subject.

No it is not just a bolt in swap quite a few interesting things need to be done.

The transfer cases are different the rear drive shaft needs to be changed.

Most people if they have the room bring the entire donor vehicle home so they don`t need to make numerous trips for forgotten parts.

 

Which transfer case is the more favorable?

 

probably the toyota RF1A Gear Driven Transfer Case off of a 5speed manual .

 

Stupid question...why would more splines be better? I'd figure the bigger the spline (fewer splines) would result in stronger bite.

 

23 spline has a larger diameter than 21. V6 and Turbo trucks have transmissions with 23 spline

 

the easiest is prob a w56 5speed with the RF1A Gear Driven Transfer Case which was with that from factory . those both have 21 spline . if you want 23 spline which is stronger you will need a trans from a turbo 4cyl R151F , not a common trans but worth it if you can find one or the more common v6 R150F

and you will need the RF1A Gear Driven Transfer Case but from factory it only came in 21 spline so you will have to switch it out for a 23 spline or buy one thats already installed in it. but with the v6 R150F trans you might need an adapter not sure so it will take the RF1A Gear Driven Transfer Case

 

I'd stick with the w56 with the tc that goes with it. But after realizing all that goes win a manual swap I.e. Clutch pedal, cable and master cylinder, wiring for back up lights and drive shafts. It's not worth it unless I have a donor vehicle which I don't nor can afford.

 

Acquire your parts over time. It is sooooooo worth it to perform this swap.

Find a donor vehicle and take the trans, transfer case, crossmember, clutch pedal bracket, pedals, rear driveshaft, clutch fluid lines, flywheel bolts (if possible), and pressure plate bolts (if possible).