The truck was selected for the tranny swap because the auto-box was in seriously bad shape, the motor is a recent rebuild, and the body and frame are solid and rust free.
With the help of a friend, we managed to gather the parts, deal with hiccups and complete the install in about 20 hours. The total cost was about $1500.00. $500.00 of this was due to a factory clutch, cover, and bearings. I paid someone else to pull the parts off of the donor, which accounts for the remaining $1000.00.
As there is lots of information out there on what to expect, I'll post the points I didn't find listed that would simplify this type of conversion.
1) Before removing the brake pedal assembly, you'll notice that the bracket is oversize, and outlines where the holes should be for the clutch pedal assembly. By comparing the clutch pedal assembly you can quickly eyeball where to drill the 3/8" holes in the firewall for the bolt holes on the clutch pedal assembly.
Again, before removing the brake pedal assembly measure the clutch master cylinder and punch an appropriate size hole through the firewall in the appropriate spot through the hole in the brake pedal assembly.
http://www.trdoffroad.com/gallery/displayimage.php?album=225&pos=02) Removing and installing the transmission goes much smoother if you remove the flange from the front differential.
3) The flywheel on the automatic transmission is thinner than the flywheel for your manual transmission. Track down the appropriate bolts in advance. They were only $3.00 each from the dealer, but half a day's delivery. These need to be torqued to 80lbs PSI so you don't want to take short-cuts with these.
4) When the mechanical work is done you'll have the following primary electrical issues to address:
a) Reverse lights not working.
b) Shifting to 4x4 will turn the front drive-shaft, but not engage the front diff or turn on the green 4x4 light.
c) The truck won't start
While we found various descriptions on how to solve the problem, in the end we needed to consult the shop wiring diagram to sort things out. Have one handy.
Having completed the job I would say the most frustrating part was installing a bracket to the side of the engine block near the starter to hold the clutch hydraulic line. My hands were a little large for the job.
Hopefully I'll get some pictures posted later.
