3rd GEN HILUX SURF REAR WHEEL BEARING RENEWAL
Following instructions are for the 3rd Gen Surf 1996- .These are general instructions and
show how I managed to do the job without the need for main dealer.
Parts needed new bearing front and rear oils seals.
Jack side that need doing up and support on axle stand. Release hand brake.
Remove rear wheel and brake drum, drum can be released using 2 M8 bolts in the 2
threaded holes on front of drum.
Remove hand brake cable.
Remove brake pipe using 10mm spanner, bung up the end of the brake pipe with
suitable stop to prevent too much brake fluid loss.
Un-bolt 4 x 14mm nuts at rear of brake drum; these are what hold the half shaft on.
Pull shaft out from axle, this should come out easily be ready with a rag as you may
loose a bit of diff oil.
Removal of Bearing, Locking Rings, ABS Sensor Gear & Spring Clip
Pictorial view of end of drive shaft
This is the tricky bit. Locate the 4 studs that hold the bearing housing onto the drum
and knock through to remove all 4, this gives clearance for removal of ABS sensor gear
and top locking ring.
Place plate 2 (bottom plate) under the ABS Sensor.
Bottom Plate ( 2 )
Bottom plate made from 10-12mm steel, with 54mm cut out and 4 M10 tapped holes
Place plate 1 (top plate) onto the drive shaft locating on the taper (as in diagram)
Top Plate ( 1 )
Top plate made from 10-12mm steel, with 38,80mm hole in centre and 4 x 11mm
clearance holes
Using 4 10 mm bolts start tightening from the top plate.
The top plate will hold on the taper and the bottom plate will start to come up as you
tighten the bolts bringing the ABS Sensor and the Locking Ring with it.
Take your time eventually they will come free.
With the ABS Sensor and Locking ring off the shaft remove the Spring Clip (this can be
a bit tricky you may need a hand getting this bugger off)
Turn the shaft over and locate on a good solid surface. Holding the drum bang the shaft
down with several sharp blows, this will get the other locking ring, bearing & bearing
housing off the shaft (eventually)
Nearly there now  , I removed the wheel studs and cleaned the end of the shaft to get
rid off all the old grease that had built up, it’s up to you whether you do the same.
Everything is now off the shaft.
Remove the outer oil seal from the end of the bearing housing, clean and fit new oil seal.
REASSEMBLE
Place the shaft on a solid surface; locate the plate and gasket which the wheel studs fix to
(don’t refit the studs yet)
Place the bearing housing in position (centre of drum) lightly oil the bearing housing &
centre bore of the bearing and locking ring.
Using tool similar to this
Large solid tube with end cap just bigger than diameter of drive shaft.
Place bearing onto shaft, and with tool and lump hammer, tap the bearing down until it
bottoms, taking care as it goes into the housing.
Do the same with the 1st locking ring.
Place spring clip on shaft and push down till it locates in rebate on shaft.
Lightly oil bore on ABS sensor gear, using tube and lump hammer press the gear back
in place (do not force it all the way to the spring clip, there is a gap of approx 5mm
between the spring clip and ABS gear.)
Lightly oil 2nd locking ring.
Using tube and lump hammer press the ring back in place (tapered edge of locking ring
is uppermost as this locates in the inner oil seal)
Back on the rear axle remove the inner oil seal and replace with new seal.
Inner seal is located in the axle and the best way of removal is by brute force and
destruction .
Refit inner seal by tapping round the outside with a suitable drift; take your time so as
not to damage it.
Refit the shaft, tighten all the bolt’s refit the hand break and brake pipe, bleed your
brakes, lower car remove jack and axle stand. Stand back GRIN and think to yourself
that’s just saved me £250+
This is how I did the job on both sides. I can’t really recommend it if you can’t get the tool’s. If you
have access to some oxy it will be a lot easier heating the locking rings up and smacking them off.
Any problems or questions PM me or email robsimpson1964@blueyonder.co.uk