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2003 Bontrager Service Manual
Recommended tools
15mm cone wrench
19mm cone wrench
Small slot screwdriver
Hammer (soft faced)
Cartridge bearing remover
Bearing press
DISASSEMBLY
Hub parts and names are referenced on next page.
1. Hold the left side (non-
drive) axle spacer with a 19mm
cone wrench and loosen the end
nut (Fig. 2F) with a 15mm cone
wrench.
2. Remove the end nut,
washer, and axle spacer (Fig. 3F)
from the axle.
3. Insert a thin screwdriver
blade under the bearing seal
(Fig. 4F) and pry off the seals
from both sides of the hub.
4. Tap the left end of the
axle with a hammer to drive
the axle out of the hub.
5. If inspection shows it
necessary, remove the washers
and end nut from the right side
of the axle.
To loosen the end nut, re-
install the left side axle spacer
and locknut, and lock the end
nut against the axle spacer.
Hold the axle spacer with a cone
wrench while you loosen the
right side end nut. Alternately,
hold the axle with vise grips.
6. Place a bearing removal
tool on the left bearing. With a
punch on the bearing tool, drive
the left bearing out of the hub
with a hammer.
7. If it is necessary to remove
the freehub 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. Wipe old grease or debris from the hub bearing
seats.
2. Normally, bearings are not re-used. If you are re-
installing an old bearing, wipe off any grease or debris
from both the inner and out surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
ASSEMBLY
Lubricate bearings and threads
1. Lubricate the threads on
the axle with Wrench Force™
synthetic grease, or a similar
product.
2. Lightly grease the inner
and outer surfaces of each bear-
ing where they contact the hub
shell and axle.
Assemble the hub
1. Press the right bearing onto the right side of the
axle, denoted by the smooth, non-threaded area with a
shoulder.
Note: the black seal of the bearing faces out (Fig. 5F).
2. Place the axle through the freehub body.
3. Press the bearing into the hub shell with the bear-
ing press.
4. Slide the left bearing onto the axle with the black
seal facing out. Thread the axle spacer onto the axle, and
use the bearing press to press the left bearing into the
hub. The axle should turn freely with no lateral play in
the hub shell.
5. Place the bearing seals into the hub with the let-
tered surface facing out.
6. Thread the axle spacer onto the axle. Place a 17mm
cone wrench on the axle spacer and a 15mm cone wrench
on the end nut. Tighten the end nut against the axle spacer.
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.
Rear hub- Cartridge bearing
2002/2003 Bontrager Race, Race Disc rear wheels
Fig. 1F
Fig. 4F
Fig. 3F
End
nut
Axle spacer
Fig. 2F
Axle spacer
End nut
Fig. 5F
Outside
Inside