RYAN Hawley’s bombshell return to Emmerdale has been one of soap’s best kept secrets.

The actor agreed to reprise his role as Robert Sugden on the show and has already begun filming for his comeback scenes but until The Sun revealed the news – fans were none the wiser.

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Emmerdale bosses went to great lengths to keep Ryan Hawley’s return a secretCredit: ITV

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Fake names were used on scripts to conceal his identityCredit: ITV
Now, we can reveal exactly how Emmerdale bosses managed to keep his return under wraps for so long.

Going to extreme lengths in order to keep any prying eyes from spotting him on the show’s set, show execs resorted to smuggling him in and out of the village.

They kept him hidden from public view in order to ensure no one clapped eyes on the star.

In order to keep things tight around the studio, they ever resorted to using fake names on scripts and call sheets in order to prevent any information about his return falling into the wrong hands.

A source told The Sun of Ryan’s return: “It’s the biggest secret in soapland but Robert is returning to Emmerdale.

“Ryan has a lot of respect for the show and its fans and he really wanted to give them a treat so he agreed to come back for a brief stint.

“It’s going to be a huge surprise for fans especially the Robron fans who have missed Robert desperately since Ryan quit.

“Nothing was seen as being too extreme to keep the secret with fake names on scripts, smuggling him in and out of the studios and keeping everything very tight.”

Robert’s comeback comes six years after he was last seen on the show.

He found himself jailed for killing his sister Victoria’s rapist Lee with a fatal blow to the head.

Emmerdale’s Robert Sugden attacks Al Chapman over pregnant Victoria jibe

Since being locked up in prison, Robert has cut all ties with his family and friends and hasn’t had any visitors in prison.

Unbeknown to him, his brother John has rocked up and begun a relationship with his ex-husband, Aaron.

But John has been hiding a very dark secret – he is a secret serial killer.

Whilst his family know of his involvement with Anthony Fox’s murder, they have no clue about his secret killing of Nate Robinson.

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His return comes as Aaron prepares to marry his brother, JohnCredit: Rex

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What will Robert get up to?