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HUB INSTRUCTIONS
PART NUMBER 231793 SERVICE MANUAL 2003
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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) . . . . . . . 11 Loose ball . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-13 Loose ball, double sealed (Formula FCM) .
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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 Shell shield 13mm cone wrench 1. Place eleven 3/16” balls in 17mm cone wrench Small slot screwdriver the ball cup on one side of the hub. Hammer (soft faced) 2. Place the shell shield, with its sharp edges facing out (Fig. DISASSEMBLY 6A), into the hub. The shell shield is a press fit, so must be
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Exploded view and Parts list 9 1 2 4 3 5 7 6 8 7 6 5 4 3 2 1 Pos Description Description Model year Model for Parts included (qty) TCG Part # 1 External seal Axle set 99/00/01/02 all 1(2), 4(2), 3(2), 9 68257 2 End nut Locknut set 99/00/01/02 all 2(2) 68543 3 Washer 4 Ball cone 5 Shell shield 6 Ball bearings 7 Ball cup 8
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Front hubs- Loose ball, semi-cartridge; Formula FCM '99, 2000, 2001 Bontrager Race, Race Disk front wheels Recommended tools Lubricate bearings and threads Bearing seal 13mm cone wrench 1. Lubricate the threads on 17mm cone wrench the axle with Wrench Force™ syn- Adjustable wrench thetic grease, or a similar product. Hammer (soft faced) 2. Place a bead of grease all Small slot screwdriver the way around each ball cup, sufficient to hold the balls. DISASSEMBLY Hub parts and names are reference
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Exploded view and Parts list 1 2 10 3 4 5 6 7 8 9 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 Description Model year Model for Parts included (qty) TCG Part # 1 External seal Axle set 99/00/01 all 10, 4, 2, 5(2), 11, 6(2), 3(2) 68524 2 End nut Locknut set 99/00/01 all 2(2)
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Front hubs- Cartridge bearing, alloy axle 2002/2003 Bontrager Race, Race Disc front wheels Recommended tools ASSEMBLY 17mm cone wrench 1. Press a bearing into the Special hook spanner Axle Hammer and broad punch hub with a bearing press. Note: the black seal faces out (Fig. 9C). Bearing removal tool Bearing press 2. Press the second bearing with the bearing press. DISASSEMBLY 3. Place the bearing seals Hub parts and names are referenced on next page. into the hub with the lettered Axle nut s
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Exploded view and Parts list 1 3 2 4 6 5 4 3 1 Note: Rotor adapter for disc hubs not shown Rotor spacing varies by model year, see details below. Description Model year Model for Parts included (qty) TCG Part # Pos Description Seal 99/00/01 all 3(2) 68261 1 End cap Bearing 99/00/01 all 4(2) 68262 2
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Needs photos and text Front hubs- Cartridge bearing, threaded alloy axle 2002/2003 Bontrager Race Lite Road front wheels Recommended tools ASSEMBLY 17mm cone wrench (2) 1. Press a new bearing onto Hammer and broad punch Bearing press the axle with a bearing press. Note: the black seal faces out (Fig. 4H). 2. Place the hub seal onto the DISASSEMBLY axle, and thread on the axle end Hub parts and names are referenced on next page. cap. Clamp the middle of the axle Remove the axle and tighten th
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Exploded view and Parts list 1 3 2 5 4 3 2 1 Description Model year Model for Parts included (qty) TCG Part # Pos Description Seal 02 all 2(2) 221468 1 End nut Bearing 02 all 3(2) 73335 2 Seal #6000 3 Bearing Axle set 02
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Freehub body information (non-DT Swiss) FREEHUB BODY RUNNING CHANGE INSTALLATION AND REMOVAL If the freehub body is worn or damaged, replace it. Bontrager rear hubs use an unique freehub body that Removing the freehub body in some cases has encountered removal issues. In these cases, a high amount of torque is necessary to remove or 1. Follow the Disassembly install the freehub body attachment bolt. instructions for the hub. Remove the axle, and then the right side To resolve this problem
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Rear hubs- Loose ball Bontrager Superstock, Superstock Disc, Select ATB, Select Road, Select Hybrid wheels, plus Bontrager Comp II rear hub the hub). Replace any worn parts. Recommended tools (2) 15mm cone wrench ASSEMBLY Adjustable wrench Lubricate bearings and threads Hammer (soft faced) Small slot screwdriver 1. Lubricate the threads on the axle with Wrench Force™ syn- thetic grease, or a similar product. DISASSEMBLY 2. Place a bead of grease all Hub parts and names are referenced on next p
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Exploded view and Parts list Note: 1 2 Rotor adapter for disc hubs not shown 3 Rotor spacing varies by model year, see details below. 4 5 6 7 8 9 10 11 Splined 7 6 5 3 11a 12 2 Threaded Note: There are two types of freehub body attachments; see below for specifi- cations, and page 9 from more information Pos Description Description Model year Model for Parts included (qty) TCG Part # 1 External seal Washer 99/00/01/02 all 3
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Rear hubs- Loose ball, double sealed (Formula FCM) '99, 2000, 2001 Bontrager Race and Race Disk rear wheels Recommended tools ASSEMBLY (2) 15mm cone wrench Lubricate bearings and threads 12mm allen wrench Adjustable wrench 1. Lubricate the threads on Hammer the axle with Wrench Force™ Small slot screwdriver synthetic grease, or a similar product. DISASSEMBLY 2. Place a bead of grease all Fig. 1E Hub parts and names are referenced on next page. the way around each ball cup, sufficient to hol
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Exploded view and Parts list Note: Rotor adapter for disc hubs not shown 1 Rotor spacing varies by model year, see details below. 2 3 4 5 13 6 7 8 9 10 11 6 7 12 Splined 4 3 13 2 11a Threaded Note: There are two types of freehub body attachments; see below for specifi- cations, and page 9 for more information Description Model year Model for Parts included (qty) TCG Part # Pos Description Axle set 99/00 all 10
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Rear hub- Cartridge bearing 2002/2003 Bontrager Race, Race Disc rear wheels Recommended tools ASSEMBLY Inside 15mm cone wrench Lubricate bearings and threads 19mm cone wrench Small slot screwdriver 1. Lubricate the threads on Hammer (soft faced) the axle with Wrench Force™ Cartridge bearing remover synthetic grease, or a similar Bearing press product. 2. Lightly grease the inner DISASSEMBLY Outside and outer surfaces of each bear- Hub parts and names are referenced on next page. ing where th
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Exploded view and Parts list 1 2 3 4 5 6 7 8 3 5 9 2 1 Pos Description Description Model year Model for Parts included (qty) TCG Part # 1 End nut Axle set 01/02 all 1(2), 2(2), 3(2), 4, 7, 9 211351 2 Washer Bearing 01/02 all 5 73335 3 Spacer Freehub body 01/02 all 8, 9, removal tool
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DT-Swiss Comp series hubs Important information before you begin with Comp series hubs Tool list for DT Swiss front hubs Some Bontrager front hubs utilize DT Swiss internal The following tools may be necessary to perform parts. This manual is intended for retailers with the maintenance work on DT Swiss appropriate skills and knowledge to work on these hubs. Comp series hubs: Short Please read the entire section before carrying out any Long bearing press bearing kind of maintenance work. Sho
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Comp front hub Bontrager Race Modified, Race Modified Disc front wheel, 2003 Race Lite ATB, Race Lite ATB Disc front wheel Recommended tools ASSEMBLY Comp bearing press, front hub End cap 1. Place the Comp bearing Short bearing press 17mm cone wrench press on the workbench or other Multi-purpose grease solid surface. Push a new bear- Bench vise ing onto the axle, and push the Axle vise axle into the bearing press (Fig. Hammer, soft faced 4K). Thin-bladed slot screwdriver 2. Place the hub ov
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Exploded view and Parts list 1 4 2 3 3 2 1 5 Pos Description Description Model year Model for Parts included (qty) TCG Part # 1 End cap Axle kit 99/00/01 All 1(2), 2(2), 3(2), 4 70361 2 V-seal Bearing 99/00/01 All 3 211349 3 Bearing 4 Axle 5 Hub shell 21 2003 Bontrager Service Manual
