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5. Carefully clean the star
ratchets with a dry cloth. Inspect
both star ratchets for damage.
If any damage is visible, replace
the ratchet.
5. Lightly grease both star
ratchets with DT Swiss special
grease (only).
6. Place the spacer ring
into the freehub body. Place the
spring into the freehub body
with the large diameter end in
contact with the spacer ring
(Fig. 15I).
7. Place both greased star
ratchets into the freehub body
(Fig. 16I).
8. Push the freehub body,
together with the cassette, over
the axle.
Caution: Ensure the freehub body is not tilted !
9. Pull the V-seal off the right
end cap (Fig. 13I). Clean it thor-
oughly with a cloth, lightly grease
it, and reinstall it on the end cap
with the open ‘V’ facing the hub.
10. Place the end cap over
the right end of the axle and
manually press into place.
Ensure the end cap is not tilted
and that it audibly clicks into
place.
After completing assembly of the hub, check its function
by giving the cassette a sharp, quick spin. If the ratchets do not catch, there could be too much grease
inside the freehub body, or the wrong type of grease was used. In this case, remove some of the grease
or replace it using the correct grease.
2. Push the wheel over the
tool, drive side down.
3. Place the bearing care-
fully into the hub (Fig. 12I).
4. Place the short bearing
press over the axle (Fig. 7I). Tap
the bearing into place with the
hammer.
Turn the axle and check that you do not feel any irregular
friction.
5. Lightly grease the surface
of the bearing.
6. Pull the V-seal off the
end cap (Fig. 13I). Clean it
thoroughly with a cloth, lightly
grease it, and reinstall it on the
end cap with the open ‘V’ facing
the hub.
7. Replace the completed
end cap onto the left axle end.
Install the freehub
1. Grease the splines inside
the hub shell with DT Swiss spe-
cial grease (only).
2. Push the spacer over
the axle (Fig. 14I) until it butts
against the bearing.
3. Insert the spring, with
the large diameter in contact
with the bearing (Fig. 14I).
4. Clean the outside end of the
freehub body with a clean cloth.
Before positioning the spacer and the ratchet in the freehub body, check that the freehub body bear-
ings spin freely without binding. If any binding or scratching is detected, replace the freehub body with
a new or reconditioned one.
Fig. 11I
Freehub body seal
Fig. 12I
Fig. 16I
Fig. 15I
Fig. 13I
End cap V-seal
Fig. 14I
Spacer
Spring
2003 Bontrager Service Manual
Part list on following page