Headlight Replacements, Inserts & Conversion Kits

Choosing a replacement headlight

Measure the lamp you are replacing, not the bucket. Round lamps are 178mm (7in) or 146mm (5 3/4in), and rectangular lamps are 165 x 100mm or 200 x 142mm. Those four sizes cover most older 4x4s, trucks, tractors and plant, including 40, 60 and 70 Series LandCruisers, older Patrols and Hiluxes, Jeeps and Land Rovers. Trucks and buses with modular lamps use the 90mm high and low beam assemblies in 12V 55W or 24V 70W halogen, or a 9 to 33V LED version with a built-in DRL.

Then decide sealed, semi-sealed or LED. A sealed beam is the original one-piece unit and is the cheapest like-for-like swap. A semi-sealed H4 or H1 conversion takes a replaceable halogen globe, so the next failure costs a globe rather than a lamp. An LED insert replaces the whole lamp with a sealed LED unit, with high, low and DRL in one housing, rated 9 to 33V for 12V and 24V vehicles.

Sealed beam, halogen or LED

• Sealed beams use a 2-pin (high beam only) or 3-pin (high/low) terminal. Match the pin count and wattage, for example 12V 60/40W or 24V 60/50W.
• H4 conversion kits ship with the lamp, globe and connector. H4 is high/low in one globe. H1 is high beam only and goes in the outer lamp of a four-headlight setup.
• LED inserts from JW Speaker and Narva are ECE or ADR approved as complete lamps, which is the compliant way to go LED. LED conversion globes in a halogen housing are sold for off-road and plant use, as a halogen lamp is not approved with an LED globe in it.
• Buckets and housings are separate line items in plastic or steel, open or closed back, for a lamp that has lost its mount.
• Check the beam pattern after fitting. A replacement that is aimed high will get you pulled over faster than a dim one.

What else you might need

Globes: H4 and H1 halogen upgrades for semi-sealed lamps, from standard to Plus 50 and Plus 60 output grades.

Daytime running lights: a separate DRL kit if the replacement lamp does not include one.

Wiring kits: a headlight relay harness takes the load off 30-year-old switch contacts.

Driving lights: for distance beyond what any headlamp will do.

Frequently asked questions

How do I know which size headlight I need?

Measure the diameter of a round lamp or the width and height of a rectangular one across the glass. 178mm is 7in, 146mm is 5 3/4in, and the two rectangular sizes are 165 x 100mm and 200 x 142mm.

Are LED headlight replacements legal in Australia?

A complete LED headlamp insert that carries ECE or ADR approval is. An LED globe fitted into a halogen headlamp is not, because the lamp was approved with the globe it was designed for.

What is the difference between H4 and H1?

H4 is a twin-filament globe that does high and low beam in one lamp. H1 is single filament and used for high beam only, or for the outer lamps on a four-headlight vehicle.

Will a 7 inch LED insert fit my 70 Series?

Yes, a 7in (178mm) round insert is the size 70 Series LandCruisers, older Patrols, Jeeps and Defenders use. Check whether your vehicle needs an adaptor harness for the factory plug.

Popular headlight replacement brands

We stock replacement headlamps, inserts and conversion kits from Narva, JW Speaker, Ignite, Roadvision, LED Autolamps and LV Automotive.