A few more updates...
A couple months ago one of my sealed beam headlights burned out and I finally got around to replacing it last week. I decided to get some roundeyes for it and get rid of the dated sealed beams. The install was super easy and I am pretty pleased with the way it turned out. I left the stock replacement 60/55 bulbs for now but may upgrade the harness and bulb later. Sorry for the crappy pics taken in the dark cramped garage...
Before:
After:
I also just realized I never posted info about the completed 4WD setup. If you recall I opted not to convert the t-case to manual shift, but keep the vacuum shift system despite all the problems I have read about from 62 owners. I like the push button shift on the fly feature and for me it has always been reliable. I can see how with a gas engine it may be different because the vacuum systems are a lot more complicated making trouble-shooting difficult and more prone to leaks. On the other hand, the 1HZ vacuum pump produces plenty of consistent vacuum, about -90kpa (~27 in.Hg) at idle and the only things on the system are the brake and clutch booster, the 4WD and the fuel pump compensator. very simple.
The HJ shift setup, from what I could tell, is exactly the same as the FJ62 only the solenoids have fixed wiring (no plugs) and are 24V. I talked a little about the wiring
HERE but never revisited the results. I had to modify the solenoids slightly to attach them to the HJ bracket and to accept a FJ62 harness pigtail. The threaded hole existed on the FJ60 firewall and it bolted right up.
This winter was the first time I really used the 4WD and I found it was really slow to engage. I finally got around to looking at it yesterday and I discovered that one of the hard lines was clogged just before the t-case. I used the lines off a 62 parts rig which were in better shape than the HJ units, but I guess I forgot check this one closely
. Anyway, now the system works perfectly and the t-case shifts instantly.