Headlight upgrade kit question Koito / Toyota FJ40 - Part Number 81110-60P70

[Kringle]

I got this kit today for my 1970 40 series. I know it's pretty plug and play simple as far as wiring goes. My question is that my headlight buckets don't have a large enough hole to accommodate the plug on the new harness. I know a lot of people have done this upgrade..... did you have the same issue? How did you solve it? Just drill a hole in the bucket? or is there some easy hack I'm missing here? Maybe I have some funky non stock buckets?

Thanks for any help you can offer

 

[MOTOV8R]

Maybe pull the rubber cover back on that plug and remove the wires, put them through the hole then re wire the plug?

 

[cruisermatt]

We drill the buckets or swap to the later bucket setup.

Be sure to check out my mounting bracket kit for the relays and fuses on my website

 

[Green Bean]

We also have the closed-style headlight buckets on our 1970 40 series. It has been a few years so my memory is a bit sketchy but I seem to recall that the headlight harness has a connector upstream of the plug. I believe that you plug in the headlight and feed back the harness from inside the bucket through the existing hole. I might have had to enlarge the hole slightly, but not very much. Don't forget your new grommet.

 

[Green Bean]

If I recall correctly, this is the little in-line connector that allows you to disconnect the harness in order to feed the wires back through the closed bucket.

 

[Green Bean]

We drill the buckets or swap to the later bucket setup.

Be sure to check out my mounting bracket kit for the relays and fuses on my website

Huge shout-out to Cruiser Matt's Off-Road for his amazingly fast service. I placed an order at 8:42 A.M., and received notification of shipping and tracking info at 8:46 A.M. Now that is quick. Keep up the great work Matt. This forum is very fortunate to have you as a vendor and exceptional mechanic.

 

[cruisermatt]

If I recall correctly, this is the little in-line connector that allows you to disconnect the harness in order to feed the wires back through the closed bucket.
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I don't think that is part of the normal H4 kit - do you have LED's? Those look like LED connectors.

Huge shout-out to Cruiser Matt's Off-Road for his amazingly fast service. I placed an order at 8:42 A.M., and received notification of shipping and tracking info at 8:46 A.M. Now that is quick. Keep up the great work Matt. This forum is very fortunate to have you as a vendor and exceptional mechanic.

You did get it in right at morning coffee/email/packing order time. I appreciate your order and your patronage.

 

[Green Bean]

I don't think that is part of the normal H4 kit - do you have LED's? Those look like LED connectors.



You did get in right at morning coffee/email/packing order time

I for got all about the LED swap; now that you mention it maybe that is why I was bale to feed the wires through the hole in the back of the closed bucket. My apologies to the OP for any confusion that I created.

 

[Skreddy]

On my 1970, I pulled the wires out of the plastic connector and fed them through the grommet and little hole in the bucket. I also shortened the wires considerably. Mounted my relays off the top passenger side of the radiator support.
Mine’s blue also so should work the same for yours…..

A side note from pulling the wires from the plug; the high and low beam wires were switched from Toyota. This was the case for the kits I got for my 40 and my 60.

 

[mattressking]

On my 1970, I pulled the wires out of the plastic connector and fed them through the grommet and little hole in the bucket. I also shortened the wires considerably. Mounted my relays off the top passenger side of the radiator support.
Mine’s blue also so should work the same for yours…..

A side note from pulling the wires from the plug; the high and low beam wires were switched from Toyota. This was the case for the kits I got for my 40 and my 60.

Yes - this is the right way to do it, it's super easy. I'd recommend taking this time to cut down the wiring harness and crimp on new H4 terminals to shorten the harness.

 

[Green Bean]

We drill the buckets or swap to the later bucket setup.

Be sure to check out my mounting bracket kit for the relays and fuses on my website

Installed the mounting relay and fuse mounting bracket kit. Thanks @cruisermatt!

 

[OlYellr]

We drill the buckets or swap to the later bucket setup.

Be sure to check out my mounting bracket kit for the relays and fuses on my website

I can vouch for the bracket kit too. Well worth it.

 

[sleepycruiser]

We drill the buckets or swap to the later bucket setup.

Be sure to check out my mounting bracket kit for the relays and fuses on my website

Installed the mounting relay and fuse mounting bracket kit. Thanks @cruisermatt!
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I can vouch for the bracket kit too. Well worth it.

View attachment 3671944
View attachment 3671945

Nice…just ordered a set from @cruisermatt

I was wondering how to mount all that easily.

 

[lazarus18]

Hey everyone, I wanted to ask here as I didn’t see where to find this info.

I purchased the H4 headlights from city racer for my 1970 40, however I am wanting to remove the old buckets and swap for later model 40 bucket set seen in photo below.

I was given a ton of parts by a friend recently for headlights but am noticing I might not can swap the buckets as the later model (seen above) seems to be to big and won’t fit through the headlight housing holes on the bib for my 1970 year.

Any suggestions or will I just have to keep the old buckets and more than likely drill the holes like @cruisermatt said above? I have a radiator overflow that I was going to try and fit in but not seeing how it’s possible with the old style buckets as they take up alot of space.