Bontrager 231793 Comp rear hub, Installing the pawl spring and pawls, Install the freehub body

Comp rear hub

Bontrager Race Modified rear wheel, 2003 Race Lite ATB, 2002/2003 Race Lite Road rear wheel

Fig. 1G

Spacer

Fig. 2G

Fig. 3G

Retainer

springPawl

Fig. 4G

Recommended tools

Long bearing press Short bearing press 17mm cone wrench Multi-purpose grease Bench vise

Axle vise

Hammer, soft faced Thin-bladed slot screwdriver

DISASSEMBLY

Hub parts and names are referenced on next page.

1.Place the axle vise in the bench vise and clamp the left- hand end of the axle.

2.Remove the cassette.

3.Loosen the right end nut with the 17mm cone wrench and remove the end nut (Fig. 1G).

4.Pull off the freehub body with your fingers.

The spacer (Fig. 2G) may be stuck to the inside of the free- hub body with grease.

5.Remove the spacer (Fig. 2G).

6.With the wheel removed from the vise, tap the right end of the axle with the hammer until loose. Pull the axle from the left side of the hub shell (Fig. 3G).

7.Place the right end of the axle into the axle vise.

8.Loosen the left end nut with the 17mm cone wrench, and remove it from the axle. Also remove the bearing.

9.Remove the retainer spring (Fig. 4G) and pawls from the hub with the screwdriver.

10.Pull the roller bearing retainer from the hub (Fig. 5G).

11.From the left side of the wheel, place the axle through the hub and the bearing. Tap the axle with the hammer to drive the right hub bearing out. Remove the bearing from the axle.

Clean and inspect the parts

2.Place the wheel over the axle with the drive side facing up.

3.Place a new bearing over the axle, black side out. Tap the short bearing press with the ham- mer to begin pressing the bearing into the hub (Fig. 7G).

4.Leave the short bearing press in place, and lift the wheel from the long bearing press (in the vise). Remove the axle from the hub and replace the wheel over the long bearing press.

5.Again tap the short bear- ing press with the hammer to press the bearing into the hub.

This is an important step, which ensures the bearing is cor- rectly pressed in.

6.Turn the wheel over and place it drive-side down on the long bearing press. Push the short 33mm end of the axle through the hub and bearing.

7.Slide the second hub bear- ing over the axle, black side on top.

8.Tap the short bearing press with the hammer to press the second bearing into the hub.

9.Turn the wheel over. Lightly grease the bearing shell.

10.Slide the roller bearing retainer over the hub bearing and into the housing (Fig. 8G). Be careful not to dislodge any roller bearings.

Installing the pawl spring and pawls

1.Place the pawl spring over the axle and install the spring into the retainer body with the elbow pointing up (Fig. 9G).

2.Push both pawls beneath the spring with a screwdriver (Fig. 10G). Make sure they are placed correctly (Fig. 11G).

3.Lightly grease the roller bearing retainer, pawls, and hub bearing.

Fig. 6G

Fig. 7G

Fig. 8G

Pawl spring elbow

Fig. 9G

Fig. 5G

Clean all components and inspect them thoroughly. If any cracks or other damage are vis- ible, the parts must be replaced.

Install the freehub body

1.	Push the spacer (Fig. 2G)
over the axle.
2.	Remove the freehub body seal

Fig. 10G

ASSEMBLY

1.Clamp the long bearing press into the bench vise. Push the axle, long end first, through the hole in the press. The short, 33mm end of the axle should be on top (Fig. 6G).

(Fig. 12G). Clean the seal. If it is faulty or

damaged, replace it.

3. Clean the freehub body teeth (a

toothbrush works well).

4. Lightly grease the seal and freehub

Pawl

Spring position

Fig. 11G

22 2003 Bontrager Service Manual