I am trying to replace the headlights on my 1994 Toyota Pickup (SR5 3.0L). Every parts store tells me that I need the H6054 headlamp. However, when I tried to install it, the headlight will not fully seat into the bezel. I took a look at my old headlight, and the prongs are MUCH shorter than the replacements. The longer prongs on the new ones make it so the plug hits the back of the bezel. The guys at the store didn't know what to do, and told me I might just have to grind them down. Is there a reason I can't find a headlight that fits without grinding?

Edit: Here are some photos

1994 Pickup SR5 3.0L

The new bulbs prongs are much longer, forcing the female plug to hit the back

I know... so much cake!

I've already returned the new bulb, but if I guessed, its prongs are 1/2" longer.

Old bulb. The blue printed bulb ID on the back is so old that it's worn away. All that's legible is "Sylvania"

 

Hmm, I have H6054 on my ride.
They fit with no issues.
Maybe some pics of your situation, might get some responses.

 

I have Sylvania H6054 head lights in my Truck too, and they fit just fine (although I have a 1987 Truck, yours should be the same).

What type was the old headlight? Have any modifications been done?

Pictures would definitely help.

 

Also if your replacing a aftermarket sealed unit sometimes they have the part# somewhere on them.

 

Added some pictures. Sorry they are so large...I have no idea how to resize them.

 

Tell me if I'm wrong, but shouldn't that connector be coming out of the hole directly behind the light?
That could be your problem. Something doesn't look right, at-least to me.
Maybe old87yota can see it.

 

I don't think that's the problem. The male/female plug doesn't even seat all the way with the new bulbs. There's about a 1/4" gap where it looks like it hasn't been pushed all the way in when fully pressed in.

 

Maybe not, but looking at the picture of that connector, its pretty corroded and might not be seating all the way, just a thought.

 

When holding the new/old side by side, the old prongs are much shorter

 

I have to go to work for awhile, but when I get home I will take some pictures for comparison, maybe it can be useful.

 

My Truck has the same bulbs as your old one which I think Sylvania calls their Basic series.

I also have plenty of room behind the driver's side headlight because the 22R engine doesn't have any air cleaner parts in that area.

I do have some Sylvania XtraVision series H6054 Sealed Beam bulbs new in the box that I bought as spares a year ago that has the same length prongs as your old one (just under 3/4"), so you might want to give those a try if you can find any. The parts stores in my area are not that consistent with what sealed beam bulbs they carry.

You also should pickup some electrical contact cleaner and some dielectric grease. Spray down the connectors with the electrical contact cleaner and get all the grime out of the connectors and then put a dab of dielectric grease to keep out moisture.

 

Looks like light prongs on mine are the same as your old ones.
Just a tad under 3/4" Sorry probably no help.
Try the ones Jake suggested.
These H6054 fit quite a few vehicles I noticed.
l

 

Any front end damage? For some reason it looks like the clearance hole is offset and not centered .
So what exactly is behind the headlight?
I know a lot of people would cringe at this but have you considered clearancing the area behind your head light housing to make it fit?

Might be time to consider upgrading to a replaceable bulb style housing. Also clean up your connectconnections, lots of crap on there, a little clean up and swapping to a different housing opens up a ton of bulb options that would improve night time driving

 

I had the same thing happen!!!
I’m going to call Sylvania tomorrow (I tried calling just now but it’s after business hours).
Anyway, I had one headlight go out and decided to replace them both. There were 2 left on the shelf at the store, one box appeared to have been opened and taped back shut, but since it was the last one I bought it. The first one I replaced from the factory sealed box fit no problem, but the one that came out of the taped up box had extra long prongs.
Maybe I bought the one you returned.
I didn’t take photos of the other new one because I had already replaced it and didn’t want to take the time to dismantle it again, but again; of the two I bought, one was the same length as the old ones, and one had extra long prongs.

Old & new side by side

Old showing brand and part #

New showing brand and part number

Old prong length

New prong length

 

Don't see what the big deal is. Just cut the prongs down.

A cutoff wheel on a Dremel would make short work of it.

 

Yep, as millball said, just cut down the prongs to fit, then sand the cut edges smooth.

I do not know why some are made with longer prongs.

As I said above, the Sylvania XtraVision series H6054 Sealed Beam bulb has the shorter prongs (at least at the time I purchased them).

So far, I am liking the XtraVisions better than the Sylvania Basic series, and they should last longer too!

 

I have a 92 Toyota Truck 2wd had the same problem and the ones made in USA had the shorter plug and the ones made in China have the longer plugs