I’ve been through a few attempts to improve the headlight situation on this ’96 4Runner. The most recent being what I thought was a set of OEM headlights off a ’99 4Runner at Pick-n-Pull. The ’99-’02 models had clear glass lenses. It was a definite improvement but months later a friend pointed out that the right light was actually TYC. I’d just assumed they were both OEM.
This same friend had upgraded his lights to use higher wattage bulbs but that required relays and other electronic things I knew nothing about. But after he pointed out my TYC headlight I couldn’t let it go.
I’d seen several videos of DIY retrofits but it had seemed beyond my capabilities. Then I remembered the lower ball joints, valve cover gaskets, timing belt with crank and cam seals, and so on… Hell, I could do retrofits! What could go wrong?
So I set my sights on a 2 1/2 inch bi-xenon kit from The Retrofit Source. But even with all the posts on t4r.org I still had questions about centric rings, harnesses, shrouds and more. So I emailed TRS, expecting a speedy reply. After a week they still hadn’t responded or answered the telephone so I emailed DDM Tuning. They answered my questions in 2 hours. And their prices were so much cheaper I was able to order their 3 inch D2S kit for the same price as the 2 1/2 inch H1 kit from TRS.
March 26, 2022
I ordered a set of TYC lights for the project so I’d still have a working set should something go awry.
The TYC housings would work fine since I’d be replacing the guts. I just needed the housings and glass lenses.
March 31, 2022 (Happy Birthday, Henry!)
I baked the first light at 275 for 9 minutes. It was about a minute too long as the sealant became very soft and stringy. And that shit’s sticky, too. The next light I baked for 7 minutes and it came apart cleaner.
The D2S Projector
Trimming the Shrouds
The blue tape is just covering the sealant.
Realized they didn’t send the D2S adapter cables.
The adapter cables connect the ballasts to the bulbs. DDM had them to me in 48 hours.
April 5, 2022
Wrapped up some client work and had time to scope out the connections (with adapter cables)
April 6, 2022
Had to grind down the housings so I could fit a wrench in there to tighten the projector rings. Then I cleaned up the bowls with what I assume was Windex and test fit one of the shrouds.
April 7, 2022
Had to scope out where to mount the ballasts, route the harness, relocate the hood lighting switch and some other things. Then I dry fit everything and did some testing. The blue tape is at 38 inches. It looked good at the time. I like how it’s a distinct beam instead of scattered light from the reflector bowl.
April 8, 2022
I baked the lights for about 7 minutes at 275 and remounted the lenses with some RetroRubber resealing glue. I cracked the lip of the right lens when I was squeezing it together to get the clip on. Hopefully the clear RTV will seal it up. I don’t think it was too major. Worst case scenario, I know where I can find a glass lens from a right TYC headlight.
Finally got everything put back together. All the kids paint the inside of the housings either black or whatever matches their 4Runner. They also add halo lighting that blinks and flashes with the turn signal or any number of wild things. Not this old man. Keeping it simple. Get off my lawn.
The only place I could find with a semi-flat parking lot and a “wall” was the Arts & Craps center. Adjusted them to 2 inches below headlight centerline at 25 feet. It’s a good start.
Before/After
What went wrong? Aside from a delay with the D2S adapter cables and me cracking the lip on the lens, nothing. If that RTV doesn’t hold I’ll be swapping in a fresh lens. But now I know what the hell I’m doing. Huge thank you to everyone at T4R.org.
Used ’99 Talls
Leave a Reply