Bonnet Lift Gas Strut Kit Install Guide: 3rd Gen

The gas struts replace the bonnet prop rod so the bonnet holds itself up. Each side gets a bracket riveted under the bonnet and a ball stud on the engine bay side. Plan it out before you drill and it's a straightforward afternoon job.

3rd Gen Hilux Surf with the bonnet gas strut kit fitted
Fits
3rd Gen 96-02
Tools
Drill, 4mm bit, rivet gun
Involves
Drilling under the bonnet

What's in the box and what you'll need

In the box

  • 2 bonnet brackets
  • 4 rivets
  • 2 gas struts
  • 2 lower ball studs with washers
Gas strut kit parts: bonnet bracket, rivets, strut, washer and lower ball stud

Tools

  • Tape measure, masking tape and a pen
  • Drill and a 4mm drill bit
  • Rivet gun
  • A standard tool kit and a small flathead screwdriver

Before you start

Look along the inner sides of your engine bay where the struts will sit when the bonnet is closed. Washer bottles, hoses and accessories sometimes sit in the way and need moving a little. It's easier to find that out now than halfway through.

Fitting it, step by step

Step 1: Choose where the lower stud goes

The lower ball stud bolts into one of the factory mounting points along the top of the inner guard. Use a point no further back towards the firewall than the third one. Pick one that's free on both sides of the engine bay so the struts match.

Lower ball stud fitted on a 1996 KZN185 inner guard

Step 2: Mark the bonnet bracket position

Put masking tape under the bonnet and mark where the bracket will go. It should be no more than 120mm in from the inner skin of the bonnet.

Measuring the bracket position under the bonnet
Bracket position marked on masking tape under the bonnet

Step 3: Drill and rivet the bracket

Drill the holes out to 4mm, then rivet the bonnet bracket on with the supplied rivets.

Bonnet bracket riveted in place

Step 4: Repeat on the other side

Do steps 1 to 3 on the other side. Check the space where each strut will fold down when the bonnet shuts is clear, and move any hoses or accessories that are in the way.

Engine bay showing the areas that need to be clear for the struts

Step 5: Fit the struts

The circlips come already fitted on the strut ends. Prise each one off with a small flathead screwdriver, press the strut firmly onto the ball stud, then refit the circlip. If the circlip won't go back on, the strut isn't fully seated on the stud. Push it on further and try again.

Finally, open and close the bonnet a few times and check the struts don't catch on anything.

Gas strut fitted and holding the bonnet open

Common questions

I can't find the circlips

They're already on the ends of the struts, so they're easy to miss.

Can I still use the bonnet prop rod?

You won't need it once the struts are on.

Still stuck? Sing out.

Send a photo of where you're at and we'll help you sort it. We usually reply within a couple of hours.

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