6
2003 Bontrager Service Manual
Recommended tools
17mm cone wrench
Special hook spanner
Hammer and broad punch
Bearing removal tool
Bearing press
DISASSEMBLY
Hub parts and names are referenced on next page.
Remove the axle
1. Remove axle end caps
(Fig. 2C) by sliding them out of
the axle with your fingers.
2. Hold the axle with a
17mm cone wrench (Fig. 3C)
while loosening the axle nut
with the special hook spanner
(Fig. 4C).
3. Partially unthread the
axle nut (Fig. 5C) until it
slightly protrudes past the end
of the axle.
4. Tap the axle nut with a
soft-faced hammer until the axle
slides through the opposite bear-
ing. Once loose, the axle should
come out with your fingers.
5. Remove the axle nut, and
extract the axle (Fig. 6C).
6. Gently insert a thin screw-
driver blade between the bearing
seal (Fig. 7C) and bearing. Pry
off the bearing seals from both
sides of the hub.
7. Insert a bearing removal
tool into the bearing. Place a
blunt punch through the hub
and against the bearing removal
tool. Tap the punch with the
hammer to drive the bearing out
of the hub (Fig. 8C). Repeat for
the other bearing.
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 outer surfaces.
Do not use solvent on the bearing, as the solvent will
contaminate the grease. This may cause bearing failure.
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 bearing.
ASSEMBLY
1. Press a bearing into the
hub with a bearing press.
Note: the black seal faces out (Fig. 9C).
2. Press the second bearing
with the bearing press.
3. Place the bearing seals
into the hub with the lettered
surface facing out.
6. Insert the axle through the
hub from either side.
7. Thread the axle nut onto
the axle.
8. Hold the axle with a 17mm
cone wrench and tighten the axle
nut with the special hook span-
ner until finger tight.
Do not over-tighten the axle nut. The axle should turn freely
with no lateral play in the hub shell.
9. Press the axle end caps
into both ends of the axle.
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. 1C
Fig. 3C
Fig. 6C
Fig. 7C
Front hubs- Cartridge bearing, alloy axle
2002/2003 Bontrager Race, Race Disc front wheels
Fig. 2C
End caps
Fig. 5C
Axle
Axle nut
Fig. 8C
Bearing
seat
Fig. 9C
Fig. 4C
Axle nut
