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2003 Bontrager Service Manual
Recommended tools
(2) 15mm cone wrench
Adjustable wrench
Hammer (soft faced)
Small slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
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,
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
necessary, remove the ball cone,
washers, and end
nut from the right
side of the axle.
9. Remove the
ball bearings (Fig.
6D) from both
sides of the hub.
10. If it is
necessary to
remove the free-
hub body, refer
to the Freehub
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-
ning 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.
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
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
wrench and turn the end nut with
another 15mm cone wrench.
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.
Fig. 1D
Fig. 3D
Fig. 2D
Fig. 5D
Fig. 6D
Fig. 7D
Fig. 8D
Seal not seated
Rear hubs- Loose ball
Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub
Fig. 4D
Ball cone
End
nut
Large
washer
Spacer
Small
washer
Axle