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1989 Trooper Round Headlight Conversion Experience

1475 Views 22 Replies 8 Participants Last post by  furiousbob
As some of you may know if you've been following along in my other thread, I decided to tackle the "round eye" headlight conversion on my '89 Trooper. I completed the swap today, and it came out GREAT! I'd like to use this thread to share my experience, photos, and tips. I had numerous road blocks and questions even after studying the various good guides on this forum.

Here's some useful threads:
Some of my purchase details/parts I used:
  • A reproduction round-eye grille from National Autobody Parts Warehouse (thread) (grille link)
  • Basic Sylvania 7" sealed beams (link)
  • Aftermarket '81-86 turn signal housings from eBay — note: these use #1156 and #53 bulbs (link)
  • A NOS emblem from eBay (link)
  • A 9003-to-9004 adapter from eBay (link)
  • A set of round headlight buckets and hardware from @turnerd who graciously sold them to me (Thank you!)
  • A box of Toyota A14267 screw grommets for securing the grille to the radiator support from Clips and Fasteners (link)
  • A box of Toyota A21331 screw grommets to both replace the headlight bucket adjustment screw grommets as well as secure the edges of the grille (behind the side markers) to the radiator support (link)
  • Universal 4-pin connectors for re-wiring the side markers (link)
  • Various screws and other hardware for securing everything in place, namely:
    • 11x #12 x 3/4 stainless sheet metal screws (grille to core support)
    • 4x #10 x 3/4 stainless sheet metal screws (grille to core support)
    • 4x M4 x 1" stainless machine screws + washers and nuts (headlight buckets to core support) (you can also use #10 x 3/4 screws w/o nuts on the back ... easier install, possibly less secure?)
    • 8x nuts + washers to secure side markers to grille (your size/thread depends on side markers)
    • 6x M4 x 1/4 screws to secure the retaining rings to the buckets (not required; I needed replacements)
Automotive parking light Land vehicle Vehicle Car Vehicle registration plate

Wheel Automotive parking light Tire Automotive side marker light Land vehicle
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SIDE MARKERS:

The side markers are by far the most difficult part of this process if you don't have multiple donor trucks or a pick-n-pull to cannibalize. Thankfully you can get most of this done without removing much; just wire up the "new" '81-86 side markers outside of the truck, and update the truck's side marker wiring by just removing the two Phillips screws and pulling the housing, getting access to the cables.

So, the aftermarket '81-86 side markers I got from eBay had different wire colors than stock. This is fine, but all of the guides were written using stock components pulled from a donor Trooper, so a lot of the guidance was to just match up wire colors w/o any real info on what light should do what. The side markers have 3 "sections": a large main amber, a mini protruding amber, and a clear. Yours may vary, as there's some full-amber ones, but hopefully this breakdown is still helpful.

From each bulb socket stem two wires, a power and a ground. These are spliced in various ways into a 3-prong connector - my setup mimics this. Here's a couple diagrams for the side markers + how I wired them up:
Automotive lighting Font Audio equipment Electronic device Automotive tire

Circuit component Handwriting Audio equipment Technology Font


Here's some info on how STOCK '81-86 lights are laid out, with some color matching for clarity:
Handwriting Font Technology Display device Darkness
Gas Engineering Electrical wiring Machine Auto part


I didn't need to separate the turn signal and parking light grounds, but the stock harness on the '87-91 Troopers have two 2-pin connectors, one for turn signal and one for parking lights. The separate grounds let me match these cleanly. Here's some photos of how I wired up the other side of the side marker - the truck side. I left both stock bulb sockets in place so I could switch back to the '87-91 style grille without any more cutting and splicing and whatnot.

Gas Electrical wiring Cable Auto part Wire
Hood Automotive tire Motor vehicle Automotive lighting Automotive exterior


Here's how the truck side looked when it was ready to go, with the other bulb sockets taped off and pushed back behind the radiator support:
Tire Wheel Automotive tire Hood Motor vehicle
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HEADLIGHT BUCKETS:

@turnerd 's headlight buckets arrived having seen better days. No worries, though - got these cleaned, primed, and painted. Got new stainless hardware.

Before:
Automotive tire Wood Gas Plant Circle
Collar Auto part Automotive exterior Helmet Personal protective equipment


After painting:
Rim Auto part Circle Bicycle part Font
Synthetic rubber Automotive tire Audio equipment Font Bicycle part


After reassembly with new hardware (note, this is where I used 4x of the Toyota A21331 screw grommets)
Automotive tire Synthetic rubber Rim Carbon Font
Eyewear Idiophone Tints and shades Rim Bumper
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HEADLIGHTS:

The buckets mounted right up to the radiator support on my '89 with no problems whatsoever. There are already mounting screw holes (two on each side) and cutouts for the back of the adjustment screws. I used some basic M4 stainless hardware to bolt the buckets to the support. This is where you need to remove the coolant overflow tank and battery for best access, if you didn't already when you removed the rectangular headlights.

As to not cut into or otherwise alter the stock headlight harness any more than I already did for the side markers, I purchased two short 9003-to-9004 adapters off of eBay. The stock '87-91 rectangular headlights use a 9004 (the same style connector is also used for 9007 connectors, where two cables are swapped. Most adapters come with instructions for which cables go where inside of the connector for both 9004 and 9007. Just know that it's 9004 for our use case) and the round headlights use 9003 (also called H4).

9003-to-9004 adapter:
Circuit component Coil spring Cable Electrical wiring Gas


How it connects to the headlights (I wrapped the exposed contact portions in electrical tape) (Universal headlight dust covers are on the way)
Motor vehicle Automotive tire Coil Electrical wiring Automotive wheel system

Motor vehicle Automotive tire Hood Bumper Automotive fuel system


Headlight mounted up:
Grille Plant Automotive lighting Hood Vehicle


Radiator support, with both '81-86 holes and '87-91 holes:
Automotive tire Motor vehicle Bumper Gas Automotive wheel system


Headlight bucket orientation:
Automotive tire Plant Motor vehicle Bumper Hood
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FWIW what you are calling 9003 is usually called H4. Just putting it in here in case someone down the line gets confused.
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FWIW what you are calling 9003 is usually called H4. Just putting it in here in case someone down the line gets confused.
Yep, totally true. I’ll add clarification. So many names!
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Excellent writeup! Yours has the honor of going with all the other threads I've bookmarked over the years! 😸

Looks great, now we've got to talk about that front bumper!!!! 😹 :ROFLMAO:
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Excellent writeup! Yours has the honor of going with all the other threads I've bookmarked over the years! 😸

Looks great, now we've got to talk about that front bumper!!!! 😹 :ROFLMAO:
It has also earned a sticky.
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Excellent writeup! Yours has the honor of going with all the other threads I've bookmarked over the years! 😸

Looks great, now we've got to talk about that front bumper!!!! 😹 :ROFLMAO:
Yeah yeah yeah, one thing at a time!! I’ll either need to bend it out or find a replacement
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(y) 😸
GRILLE:

Here's a diagram for the 15 total grille mounting points. Unlike the '87-91 grille's finicky clips, the '81-86 grille is screwed into place. I used the two different types of screw grommets ... more details below:
  • The top four and (middle single) red marked mounting points are a piece of cake to access. I'd do these first, but don't tighten them down yet, since they're valuable to hold/hang the grille in place. I used the Toyota A14267 grommets, pressed into the five marked locations, then metric #12 x 3/4 stainless hardware + washers to secure the grille. Worked great.
  • The four edge mounting points work differently than the rest. There are holes in the radiator support through which you can thread screws into the grille from the back side. I pressed Toyota A21331 grommets (4 total, 2 each side) into the grommet holes on the back of the grille, then reached in with a stubby Phillips driver and screwed them in from the back. Washers can be useful here as well. Note: I genuinely wasn't able to access the bottom left green mounting point (bottom of passenger side) but I made the executive decision to leave it out. I seems plenty sturdy. If you can access it easily, great. I had to get the coolant reservoir and battery out of the way to even have a chance at these.
  • The six bottom yellow mounting points are the most odd, in my opinion. With the 9 other (red and green) screws installed, there was a ~3/4" gap between the grille's mounting tabs and the top of the lower fascia. It's designed such that you can use a looooooooong screwdriver from the top gap in the grille to screw (if everything went as planned, #12 x 3/4 hardware into Toyota A14267 grommets, just like the red) but I also did not find any of these necessary. I snapped the grommets in, fully planning on installing the screws, but it's plenty sturdy. If I can find that aforementioned looooooooong screwdriver I might thread some in.

Automotive parking light Tire Wheel Vehicle registration plate Vehicle


The smaller grommets in the back of the grille:
Gas Screw Fastener Household hardware Auto part

Cable Electrical wiring Electronic device Auto part Wire


An example of a large grommet installed in the radiator support:
Hood Motor vehicle Automotive tire Bumper Automotive exterior


Grommets in radiator support and top of lower fascia:
Motor vehicle Grille Automotive lighting Bumper Automotive exterior
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Zip ties can be fashioned to substitute the screw-into-grommet method for most of these
Great write up, but the most important part is the new addition to your signature lol. Love it
If someone wants to use the OE part for the lower clips the PN is 8089731731
No idea if Jerry still has any but they are still available from Isuzu
Great write up, but the most important part is the new addition to your signature lol. Love it
If someone wants to use the OE part for the lower clips the PN is 8089731731
No idea if Jerry still has any but they are still available from Isuzu
Hehe, I had to!

Thanks for sticking that PN in this thread. Neat they’re still available. Also nice to have a readily-available alternative (that will probably outlast the Isuzu SKU in availability sadly)
Hehe, I had to!

Thanks for sticking that PN in this thread. Neat they’re still available. Also nice to have a readily-available alternative (that will probably outlast the Isuzu SKU in availability sadly)
hopefully Jerry has some in stock, otherwise they gotta come out of Japan.
If someone does read this and wants to order the OE clips from overseas here is the link to them.
you will need 6.
What a great write up.
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Great timing! I ordered the same grill for my 1990 and was just about to order the other parts and side marker/signal lights. One issue, where can I find the round headlight mounts? Been searching eBay and elsewhere and no dice. No pick n pull near me in NJ.
Great timing! I ordered the same grill for my 1990 and was just about to order the other parts and side marker/signal lights. One issue, where can I find the round headlight mounts? Been searching eBay and elsewhere and no dice. No pick n pull near me in NJ.
There are some on amazon that work, you will need to drill some to mount them.
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Wow. Somehow I haven't seen this post until now. Probably because it was posted after I began the parts hunt for mine... We did so many things the same, down to the same exact side markers and universal plugs! I definitely doubled up on some content. Oh well, the more guides the better. I've gone ahead and linked that one at the top of this thread too.
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There are some on amazon that work, you will need to drill some to mount them.
Thanks, I located these but thought they didn't work out for
There are some on amazon that work, you will need to drill some to mount them.
There are some on amazon that work, you will need to drill some to mount them.
I thought that poster mhamari ended up not using those because they did work and instead took the mounts off his square headlights and re-drilling. Perhaps I misunderstood. Anywhere I might find some old ones from an older round headlight Trooper? Would love to be able to bolt up without trial and error drilling.
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