Bontrager 231793 service manual Rear hubs- Loose ball, Assemble the hub

Rear hubs- Loose ball

Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub

Recommended tools

(2) 15mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver

DISASSEMBLY

Hub parts and names are referenced on next page.

Fig. 1D	Remove the axle
	1. Remove external seals
	with your fingers or a screw-
	driver (Fig. 2D). Be careful not
	to tear or mar the rubber.
	2. On the left side (non-drive)
	of the hub place a 15mm cone
	wrench on the ball cone. Place a
	15mm cone wrench on the end
	nut (Fig. 3D). Loosen the end
	nut.
	4. Remove the end nut, large
	washer, spacer, small washer,
Fig. 2D
	and ball cone from the axle (Fig.
	4D).
	5. Slide the axle, with the
	other end nut, washer, and ball
	cone still attached, out of the hub.
	6. Insert a thin screwdriver
	blade under the shell shield (Fig.
	5D) and pry off the shell shield
	from the left side of the hub.
	8. If inspection shows it
Fig. 3D	necessary, remove the ball cone,
		washers, and end
Axle		nut from the right
		side of the axle.
End		9. Remove the
nut		ball bearings (Fig.
		6D) from both
Small		sides of the hub.
washer		10. If it is
Large		necessary to
		remove the free-
washer	Ball cone
Spacer		hub body, refer
		to the Freehub
Fig. 4D
		Body section,
		pages Freehub 1
		and Freehub 2, for
removal and installation instructions.

When overhauling the hub bearings, it is usually not necessary to remove the freehub body.

Clean and inspect the parts

1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. Avoid getting solvent into the freehub, and be sure to remove all solvent thoroughly before proceeding.

2. Inspect the bearing run-

Fig. 5Dning surfaces of both the ball cones and the ball cups (inside

the hub). Replace any worn parts.

ASSEMBLY

Lubricate bearings and threads

1.Lubricate the threads on the axle with Wrench Force™ syn- thetic grease, or a similar product.

2.Place a bead of grease all the way around each ball cup, sufficient to hold the balls.

Fig. 6D

Assemble the hub
1. Place nine 1/4” balls in the
ball cup on one side of the hub
(Fig. 6D).
2. Place the shell shield,
with its sharp edges facing out,
into the hub. The shell shield is
a press fit, so must be tapped
lightly to fully seat. Lay a cone
wrench over the shell shield and
	Fig. 7D
tap the wrench with a hammer
(Fig. 7D) to protect the shield and
ensure that it is flush with the
shell.
3. Repeat Assembly steps 1-2
for the other side of the hub.
4. Tighten the end nut
against the fixed ball cone
(attached to axle) by holding
the ball cone with a 15mm cone	Seal not seated
wrench and turn the end nut with
another 15mm cone wrench.	Fig. 8D

5.Insert the axle through the hub from the right hand (drive) side.

7.Thread the ball cone, small washer, spacer, large washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out.

8.From the left side of the hub, hold the ball cone with a 15mm cone wrench and tighten the end nut with a 15mm cone wrench.

9.Check the bearing adjustment by turning the axle with your fingers. The axle should spin smoothly without binding or feeling gritty. There should be no lateral play of the axle in the hub. Readjust the hub as necessary, and re-lock the end nut.

10.Install the external seal. Make sure the seal prop- erly seals against both the end nut and the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 8D) will allow

rapid contamination of the bearings.

After completing assembly of the hub, check its function by spinning the axle with your fingers. It should rotate freely without irregular friction. A small amount of lateral play is acceptable if the play is eliminated when the wheel is installed with the quick release properly closed.

12 2003 Bontrager Service Manual