Recommended tools
(2) 15mm cone wrench
12mm allen wrench
Adjustable wrench
Hammer
Small slot screwdriver
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
1. Remove external seals
(Fig. 2E) with your fingers or
a screwdriver. 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 bearing cone (Fig.
3E).
3. Place a 15mm cone
wrench on the end nut (Fig. 4E).
Loosen the end nut.
4. Remove the end nut, large
washer, spacer, small washer,
and cone from the axle (Fig. 4E).
5. Slide the axle (Fig. 4E),
with the other end nut, washer,
and cone still attached, out of the
hub.
6. Insert a thin screwdriver
blade under the shell shield (Fig.
5E) and pry off the shell shields
from both sides of the hub.
8. If inspection
shows it neces-
sary, remove the
cone, washers, and
end nut from the
right side of the
axle.
9. Remove the
ball bearings (Fig.
6E) from both
sides of the hub.
7. If it is nec-
essary to remove
the freehub body, refer to the Freehub Body section,
pages Freehub 1 and Freehub 2, for removal and installa-
tion 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.
2. Inspect the bearing run-
ning surfaces of both the 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™
synthetic 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. 6E).
2. Place the shell shield, with
its sharp edges facing out (Fig.
6E), into the hub. The shell shield
is a press fit, so must be tapped
lightly to fully seat (Fig. 7E).
Lay a cone wrench over the shell
shield and tap the wrench with a
hammer to protect the shield and
ensure that it is flush with the
shell.
3. Repeat steps 1-2 for the
other side of the hub.
4. Tighten the end nut
against the fixed cone (attached
to axle) by holding the 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 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 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. 8E) 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.
14
2003 Bontrager Service Manual
Rear hubs- Loose ball, double sealed (Formula FCM)
'99, 2000, 2001 Bontrager Race and Race Disk rear wheels
Fig. 1E
Fig. 3E
Fig. 2E
Fig. 5E
Fig. 6E
Fig. 7E
Fig. 8E
Seal not seated
Fig. 4E
Ball cone
End
nut
Large
washer
Spacer
Small
washer
Axle
