HUB INSTRUCTIONS PART NUMBER 231793 SERVICE MANUAL 2003 HUB INSTRUCTIONS STANDARD Front Hubs Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3 Loose ball, semi-cartridge; Formula FCM . . . . . . .4-5 Cartridge bearing, alloy axle . . . . . . . . . . . . . . . . .6-7 Cartridge bearing, threaded alloy axle . . . . . . . . . .8-9 Rear hubs Freehub body information (non-DT Swiss) Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . Loose ball, double sealed (Formula FCM) . Cartridge bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 .12-13 .14-15 .16-17 DT-SWISS Comp series hubs Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Comp front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-21 Comp rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-24 Pro series hubs Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pro front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27 Pro rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-31 Please note: Many sections of this manual must be read in their entirety before performing procedures. In some cases, revised or updated information may be available on the Bontrager wheelworks website at www.bontrager.com. If you cannot find the information you need to service Bontrager wheels, please contact a technical service representative. Copyright Trek Bicycle Corporation 2002 All rights reserved 2003 Bontrager Service Manual 1 Front hubs- Loose ball Bontrager Superstock, Superstock Disc, Select ATB, Select ATB Disc, Select Road, and Select Hybrid front wheels; plus Bontrager Comp II front hub Recommended tools ASSEMBLY 13mm cone wrench 17mm cone wrench Small slot screwdriver Hammer (soft faced) Shell shield DISASSEMBLY Hub parts and names are referenced on next page. Remove the axle Fig. 1A External seal Fig. 2A Fig. 3A Axle 1. Remove external seals (Fig. 2A) with a screwdriver. Be careful not to tear or mar the rubber. 2. On one side (either) of the hub place a 13mm cone wrench on the ball cone. Place a 17mm cone wrench on the end nut (Fig. 3A). Loosen the end nut. 3. Remove the end nut, washer, and ball cone from the axle (Fig. 4A). 4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub (Fig. 4A). 5. Gently insert a thin screwdriver blade under the shell shield (Fig. 5A) and lift to remove the shield from the hub. Pry off the shell shields from both sides of the hub. 6. If inspection shows it necessary, remove the other end nut and ball cone. End nut Washer Ball cone Fig. 4A Clean and inspect the parts 1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. 2. Inspect the bearing running surfaces of both the ball cones and the ball cups (inside the hub). Replace any cones. If the cups are worn, replace the hub shell. Lubricate bearings and threads 1. Lubricate the threads on the axle with Wrench ForceTM synthetic grease, or a similar product. 2. Place a bead of grease all the way around each ball cup, sufficient to hold the balls. 2 1. Place eleven 3/16" balls in the ball cup on one side of the hub. 2. Place the shell shield, with its sharp edges facing out (Fig. 6A), 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. 5A tap the wrench with a hammer (Fig. 7A) to protect the shield Bearings in bearing cup 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 ball cone on the axle. Hold the ball cone with a 13mm cone wrench on the axle flats while turning the end nut with a Fig. 6A 17mm cone wrench. 5. Insert the axle through the hub from either side. 6. Thread the ball cone, washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out. 7. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench. Fig. 7A 8. 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. 9. Install the external seals, Seal not seated and apply grease where the seals contact the hub shell and axle Fig. 8A parts. Make sure the seals properly seal 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. 8A) 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. 2003 Bontrager Service Manual Exploded view and Parts list 9 1 2 3 4 5 6 7 8 7 6 5 4 3 2 1 Pos Description 1 External seal 2 End nut 3 Washer 4 Ball cone 5 Shell shield 6 Ball bearings 7 Ball cup 8 Hub shell 9 Axle 1999 Bontrager Comp II Description Axle set Locknut set Model year 99/00/01/02 99/00/01/02 Model for all all Parts included (qty) 1(2), 4(2), 3(2), 9 2(2) TCG Part # 68257 68543 O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm 2000/2001/2002/2003 Superstock O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm 2002/2003 Superstock Disc, Select ATB Disc O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm 2002/2003 Select ATB O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm 2002/2003 Select Road, Hybrid O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20° Spoke hole P.C.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm 2003 Bontrager Service Manual 3 Front hubs- Loose ball, semi-cartridge; Formula FCM '99, 2000, 2001 Bontrager Race, Race Disk front wheels Recommended tools 13mm cone wrench 17mm cone wrench Adjustable wrench Hammer (soft faced) Small slot screwdriver Lubricate bearings and threads 1. Lubricate the threads on the axle with Wrench ForceTM synthetic grease, or a similar product. 2. Place a bead of grease all the way around each ball cup, sufficient to hold the balls. Bearing seal DISASSEMBLY Hub parts and names are referenced on next page. Fig. 1B Remove the axle ASSEMBLY 1. Place eleven 3/16" balls in the ball cup on one side of the hub (Fig. 8B). 2. Place the bearing seal, with the lettered side facing out, into the ball cup. 3. 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 Fig. 7B over the shell shield and tap the wrench with a hammer (Fig. 9B) Bearings in ball cup to protect the shield and ensure that it is flush with the shell. 4. Repeat Assembly steps 1-3 for the other side of the hub. 5. Tighten the end nut against the fixed ball cone (attached to axle). Hold the axle with an adjustable wrench on the axle flats while turning the end Fig. 8B nut with a 17mm cone wrench. 6. Insert the axle through the hub from either side. 7. Thread the ball cone, washer, and end nut onto the axle in that order. The serrated surface of the end nut faces out. 8. Hold the ball cone with a 13mm cone wrench and tighten the end nut with a 17mm cone wrench. Fig. 9B 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 seals. Seal not seated Make sure the seals properly seal against both the end nut and Fig. 10B the hub shell. There should be a smooth transition from seal to sealing surface. An improperly installed seal (Fig. 10B) 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. Fig. 6B 1. Remove external seals External seal (Fig. 2B) with a screwdriver. Be careful not to tear or mar the rubber. 2. On one side of the hub (usually left), the cone is locked against a collar on the axle (Fig. 4B). On the other side, place a 13mm cone wrench on the ball cone. Place a 17mm cone wrench on the end nut (Fig. 3B). Loosen Fig. 2B the end nut. 3. Remove the end nut, washer, and ball cone from the axle (Fig. 4B). 4. Slide the axle, with the other end nut, washer, and ball cone still attached, out of the hub. 6. Gently insert a thin screwdriver blade between the shell shield (Fig. 5B) and bearFig. 3B ing seal (Fig. 6B). Pry off the shell shields from Axle Collar both sides of the hub. Do not attempt to pry off both shield and seal at the same time as you may damage the bearing seal. 7. Gently pry off End nut the bearing seals (Fig. Washer 6B) from both sides of Ball cone the hub. 8. If inspection Fig. 4B shows it necessary, remove the other end nut. Hold Shell shield the axle by the wrench flats (Fig. 7B) while turning the end nut with a 17mm cone wrench. Clean and inspect the parts 1. Use solvent to completely remove all old grease and debris from the hub, axle, and axle parts. Fig. 5B 2. Inspect the bearing running surfaces of both the ball cones and the ball cups (inside the hub). Replace any worn parts. Note: If the `fixed' ball cone is worn, the axle assembly (axle and ball cone) must be replaced. 4 2003 Bontrager Service Manual Exploded view and Parts list 1 2 3 4 5 6 7 8 9 10 8 7 6 5 12 11 3 2 1 Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below. Pos Description 1 External seal 2 End nut 3 Washer 4 Adjust cone 5 Shell shield 6 Bearing seal 7 Ball bearings 8 Ball cup 9 Hub shell 10 Axle 11 Spacer 12 Ball cone 1999 Race Description Axle set Locknut set Rotor adapter w/screws Disc bolt set Model year 99/00/01 99/00/01 99/00 99/00 Model for all all Hayes, RST all Parts included (qty) 10, 4, 2, 5(2), 11, 6(2), 3(2) 2(2) Not shown Not shown TCG Part # 68524 68527 991083 991153 2001 Race Disk O.L.D. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 mm Spoke hole quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28° Spoke hole P.C.D., right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45.0 mm Spoke hole P.C.D., left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58.0 mm Q.R. rod outer diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 mm Disc rotor spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 mm Rotor BCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.0 mm ...