Is there a definitive list of options for the early 4thgen 4runners 03-05 before the face-lift? I looked at the Sticky's nothing. I've seen some discussion about 06-09 but those have different housings.

Basically, it seems LED's are not a great solution with the 03-05 headlight reflector housing. My understanding is for LED's to be viable you need headlight housing with I believe projectors meant to work with LED's.

I was hoping to just throw in some LED's but the last set I tried wouldn't seat well at the back of the housing. I wheel a lot so lamps falling out isn't an option. I believe some of these LED's with large heat sinks or fans are too heavy to stay put.

Looking for recent suggestions not threads from 10 years ago. Your suggestions are appreciated.

I would choose either or, Diode Dynamics SL1's or Morimoto 2strokes. I've used them personally and they are awesome as far as LEDS in halogen bowls.

BUTTTTT.....you will always want more. So after you buy these I bet you'll be looking at headlight retrofit options. hahaha

I have budbuilt projectors and love them, avoid TEQ Customs, they lack attention to detail, the assy is rushed, and their wiring harnesses required some work to make dependable.

You are correct, stay the hell away from LED units in reflector housings. Your only safe and legal option is going to be high output halogen bulbs, some recommendations for which can be found here: 3rd Gen HID vs LED vs Halogen H11 projector headlights | Tacoma World

Keep in mind you'll need a 9006 rather than an H11, but the product line recommendations are mostly still valid. As a bonus some of the recommended bulbs are fairly cheap ($20-30 a set)

If you're really set on a big upgrade, look into upgrading to the 2006+ headlight assemblies which give you a projector housing and better light output.

I went to Diode Dynamics, this is their disclaimer.

APPLICATION NOTICE: LED bulbs are legal in the USA for Fog Light use only. Not compliant with DOT / FMVSS108 and not street legal in the USA for Headlights.

So everyone is illegally using these as headlights?

yes.