Dustcap on Freehub

[Jim77]

Hi all,

I am going to press this dustup back in but not sure how far it needs to go back on? I mean I am not sure when I need to stop.

In hindsight I should have measured it before I took it off.

Any advice would be great.

Thanks all.

Jim

[pwa]

Doesn't it just go so far and then bottom out when it gets where it needs to be?

[Jim77]

Doesn't it just go so far and then bottom out when it gets where it needs to be?

Not sure! I don’t want to press it too far so that it might affect the bearings.

[NickJP]

It looks to me like you're trying to reinstall it back to front. The lip on the inside of the dustcap should be pointing outwards.

[Jim77]

Thanks - I will reverse it.

[Mike Sales]

It looks to me like you're trying to reinstall it back to front. The lip on the inside of the dustcap should be pointing outwards.

I disagree. Take a look at the untouched side. I think that the front of the cap should be flush with the aluminium rim.

[cycleruk]

Looks back to front ?
See:- https://www.youtube.com/watch?v=X9gIEG1db0s
Depending on the tools you have you could try a socket (from a socket set) and either tap it down or use a vice to squeeze it into place.

[TheBomber]

I would call that an excess of grease. IME if you have too much thick wheel bearing grease when it works its way inside the freehub body it causes the pawls to stick. You can tell if that is happening as initially the freehub goes almost completely silent.

[Brucey]

FWIW I think that dustcap is indeed the wrong way round. It is possible to fit the dustcap too deeply and in this case the dustcap will foul the RH bearing cup during freewheeling. It is possible to re-form the edge of a steel dustcap so it fits like new. I found I had a 'williams superslim' socket which was just right for this, which probably spared me from having to make a special tool for the purpose. In those hubs which have a pressed steel dustcap, it is usually best if it is first re-formed and subsequently refitted using a slightly smaller tool. Perhaps counterintuitively, the easiest way I know of to remove them is to first knock them in too far using the refitting tool. However, doing so practically guarantees that the edge will need to be re-formed.

[gregoryoftours]

Your dust cap is the wrong way around. You can fit it the right way around, then install your cassette. The lockring will push it in almost as far as it needs to go. Then remove the lock ring and tap the dust shield in a nadge more with a socket, just enough that it doesn't rub on the lock ring when re-installed. This should give you clearance so that it isn't contacting the bearings or the lock ring.

[Jim77]

Thanks Gregory - I managed to get it back in by gently tapping it in with a screwdriver (I reversed it from the picture so it was facing the correct way) however when I turn the pedals the leave them they rotate with the cassette! What has gone wrong?!

[cycleruk]

Thanks Gregory - I managed to get it back in by gently tapping it in with a screwdriver (I reversed it from the picture so it was facing the correct way) however when I turn the pedals the leave them they rotate with the cassette! What has gone wrong?!

From your description I presume you have the back wheel off the ground and when you operate the pedals they keep going instead of stopping instead of freewheeling.
With back wheel off the ground and If you pedal backwards does the wheel turn backwards as well ?
Possibly the grease is too thick and causing stiction ?
With back wheel on the ground will the pedals/cranks turn backwards easily ?

[rareposter]

...however when I turn the pedals the leave them they rotate with the cassette! What has gone wrong?!

You've got way too much grease in there.

It's a FREEhub, not a shove-it-full-of-grease hub! It needs some light oil at most.

[Brucey]

the symptoms you describe are consistent with too much grease. However they are also consistent with the dustcap being driven in too far; easily done if the edge needs to be re-formed.

I am suspicious of the latter in good part because the OP reports refitting the dustcap with a screwdriver. IME it should not be possible to do this because the dustcap should be so tight on the lockring threads that pushing with a screwdriver risks damage. Normally the dust cap should be fitted near the end of the lockring threads, but if it is already undersize (as is often the case if it has been removed) then it will only feel tight once within the slightly smaller parallel-sided bore beyond, and refitting too deep is on the cards.