Bontrager 231793 - Manual (Page 5)

Recommended tools
13mm cone wrench
17mm 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
(Fig. 2B) with a screwdriver. Be
careful not to tear or mar the
rubber.
2. On one side of the hub
(usually left), the cone is locked
against a collar on the axle (Fig.
4B). On the other side, place a
13mm cone wrench on the ball
cone. Place a 17mm cone wrench
on the end nut (Fig. 3B). Loosen
the end nut.
3. Remove the end nut, wash-
er, and ball cone from the axle
(Fig. 4B).
4. Slide the axle, with the
other end nut, washer, and ball
cone still attached, out of the hub.
6. Gently insert a thin
screwdriver blade between the
shell shield (Fig. 5B) and bear-
ing seal (Fig. 6B). Pry off the
shell shields from
both sides of the hub.
Do not attempt to pry
off both shield and
seal at the same time
as you may damage
the bearing seal.
7. Gently pry off
the bearing seals (Fig.
6B) from both sides of
the hub.
8. If inspection
shows it necessary,
remove the other end nut. Hold
the axle by the wrench flats
(Fig. 7B) while turning the end
nut with a 17mm cone wrench.
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 ball cones and the ball cups
(inside the hub). Replace any worn parts.
Note: If the ‘fixed’ ball cone is worn, the axle assembly (axle and ball cone) must be replaced.
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.
ASSEMBLY
1. Place eleven 3/16” balls in
the ball cup on one side of the
hub (Fig. 8B).
2. Place the bearing seal,
with the lettered side facing out,
into the ball cup.
3. 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. 9B)
to protect the shield and ensure
that it is flush with the shell.
4. Repeat Assembly steps 1-3
for the other side of the hub.
5. Tighten the end nut
against the fixed ball cone
(attached to axle). Hold the axle
with an adjustable wrench on the
axle flats while turning the end
nut with a 17mm cone wrench.
6. Insert the axle through the
hub from either side.
7. Thread the ball cone, wash-
er, and end nut onto the axle in
that order. The serrated surface
of the end nut faces out.
8. Hold the ball cone with a
13mm cone wrench and tighten
the end nut with a 17mm cone
wrench.
9. Check the bearing adjust-
ment 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 seals.
Make sure the seals properly seal
against both the end nut and
the hub shell. There should be a
smooth transition from seal to sealing surface. An improp-
erly installed seal (Fig. 10B) will allow rapid contamina-
tion 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.
4
2003 Bontrager Service Manual
Fig. 1B
Fig. 3B
Fig. 7B
Fig. 9B
Front hubs- Loose ball, semi-cartridge; Formula FCM
'99, 2000, 2001 Bontrager Race, Race Disk front wheels
Fig. 5B
Shell shield
Fig. 6B
Bearing seal
Fig. 10B
Seal not seated
Fig. 8B
Bearings in ball cup
Fig. 2B
External seal
Fig. 4B
End nut
Washer
Ball cone
Axle
Collar