2002 Model 202 Rear Hub

Disassembly

  1. Loosen and remove the end fitting by inserting a 5mm hex key in each side of the hub. Turning the hex wrenches opposite of each other (standard right-hand threads) one of the end caps will loosen. There is no way to control which end cap will loosen first. If the drive the drive side end cap loosens and is removed first the freehub body may removed as well.
  2. In some cases the non-drive end cap will loosen before the drive side end cap. If this occurs, completely remove the non-drive side end cap. The axle is broached to accept an 8mm hex key. Insert the 8mm hex key from the non-drive side and holding it firmly use a 5mm hex key inserted in the drive side to loosen and remove the remaining end cap.
  3. With the drive side end cap removed by either of the above means, gently pull the cassette body away from the hub (it may help if you slowly turn in a counter clock wise direction) --STOP HERE, if you are just replacing or exchanging the cassette body. Repeat directions in reverse order. Tighten hub at 88in/lbs or torque. Warning! Fine pitch aluminum threads, do not over tighten!

Bearing Replacement

  1. Remove the cassette body as described earlier in this article. The axle may now also be removed by gently sliding out of the hub shell.
  2. Insert a flat-faced punch though the drive-side hub body bearing. Using the tip of the punch gently push to one side the spacer tube separating the two hub shell bearings.
  3. Use the punch and a small hammer to remove the non-drive hub body bearing by gently tapping against the back of the bearing ID ring on alternating sides until the bearing is worked out of the hub.
  4. Remove the aluminum spacer tube from the hub body.
  5. Remove the drive side hub body bearing as in #3.
  6. If also changing the cassette body bearings proceed by inserting a flat-faced punch though the cassette body ratchet pawl holder and use the tip to push to one side the spacer separating the two cassette body bearings.
  7. Remove the outer bearing from the cassette body by using the punch and small hammer to tap against the back of the outer bearing ID ring on alternating sides until the bearing is worked out of the cassette body.
  8. With a pair a snap ring pliers, remove the bearing retaining ring from the interior of the cassette body.
  9. Using the hammer and punch, gently tap the inner bearing from the cassette body as in #7.
  10. Replace all bearings in reverse order by pressing on the bearings' outer diameters using the appropriate sized bearing press tool.
  11. Re-install axle, cassette body and axle end fittings.
  12. Use one drop of red Loctite 262 on the axle end cap threads. Tighten axle end fittings to 88 in/lbs. Warning: Fine pitch aluminum threads, do not over tighten!

202 disc hub assembly drawing