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  1. #1
    Carpe Diem bdcheung's Avatar
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    New freehub, lots of drag

    Installed a new freehub on my Zipp 202 rear hub tonight and now there's A LOT of drag when freewheeling - enough so that any pressure on the pedals when freewheeling throws the chain off the cassette and really ****s with the RD.

    I've narrowed it down to a bearing problem - when I loosen the end caps, thereby relieving pressure on the bearings, everything is fine.

    Anyone know if the bearings just need to be broken in, or am I missing a washer/spacer/shim somewhere?
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  2. #2
    Senior Member
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    Are you applying too much preload to the bearings?

    It may just need to be run in a bit. Hard to tell how much is A LOT. Many cartridge bearings come packed fairly stiff, but loosen up within 10 or 20 miles.

  3. #3
    Isaias NoRacer's Avatar
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    Quote Originally Posted by bdcheung View Post
    Installed a new freehub on my Zipp 202 rear hub tonight and now there's A LOT of drag when freewheeling - enough so that any pressure on the pedals when freewheeling throws the chain off the cassette and really ****s with the RD.

    I've narrowed it down to a bearing problem - when I loosen the end caps, thereby relieving pressure on the bearings, everything is fine.

    Anyone know if the bearings just need to be broken in, or am I missing a washer/spacer/shim somewhere?
    Got a picture of the old freehub from the side that faces the bearings?
    2009 mileage = 14,738 miles; 2010 mileage = 15,234 miles; 2011 mileage = 17,344 miles; 2012 mileage = 11,414 miles; 2013 = 12,169

  4. #4
    Carpe Diem bdcheung's Avatar
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    @jamiewilson: "a lot" = like riding a fixed gear. Seriously.

    @NoRacer: I'm at work now but will take pictures of both cassette bodies tonight when I get home. I replaced a 202P freehub body with a 202W freehub body (so that I can use my SRAM Red cassettes).
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  5. #5
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    Unless you are man-handling your preload adjustment, then that would not account for it. I would bet that you are missing a part that is causing the preload to be applied to the inner race, binding the bearing.

    Or, just say F it and go to the track with your FG.

  6. #6
    Senior Member garysol1's Avatar
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    sounds like what my 303 did when I forgot to install the spacer between the hub and the back of the freehub.......

  7. #7
    Transplant Robobo1's Avatar
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    Quote Originally Posted by jamiewilson3 View Post
    Unless you are man-handling your preload adjustment
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  8. #8
    Carpe Diem bdcheung's Avatar
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    Quote Originally Posted by garysol1 View Post
    sounds like what my 303 did when I forgot to install the spacer between the hub and the back of the freehub.......
    I thought it was that, too, but I looked everywhere and couldn't find any spacer. It's not on the old freehub, it's not on the axle, and it's not on my workbench (which is immaculately clean).

    Also, when I put the old freehub on, everything works fine. That makes me think it might not be the washer.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  9. #9
    Carpe Diem bdcheung's Avatar
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    Quote Originally Posted by jamiewilson3 View Post
    Unless you are man-handling your preload adjustment
    Even finger-tight causes this.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  10. #10
    Senior Member garysol1's Avatar
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    Quote Originally Posted by bdcheung View Post
    I thought it was that, too, but I looked everywhere and couldn't find any spacer. It's not on the old freehub, it's not on the axle, and it's not on my workbench (which is immaculately clean).

    Also, when I put the old freehub on, everything works fine. That makes me think it might not be the washer.
    There HAS to be a spacer between the hub bearing and the freehub. Maybe it is stuck in the oil on the old freehub? Zipp does not include a spacer with new freehubs so the old one has to be reused. Look again ...maybe take a little screw driver and see if the spacer is stuck on the old body.

  11. #11
    Carpe Diem bdcheung's Avatar
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    Where on the old freehub would it be stuck? Inside, where the axle inserts, or on the very back pressed up against the part that the pawls are on?
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  12. #12
    abandoning fly:yes/land:no's Avatar
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    i'm with garysol on this one.

  13. #13
    Carpe Diem bdcheung's Avatar
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    So in this pic, my new freehub is the one on the right. where does the washer go again?

    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  14. #14
    Senior Member garysol1's Avatar
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    Quote Originally Posted by bdcheung View Post
    Where on the old freehub would it be stuck? Inside, where the axle inserts, or on the very back pressed up against the part that the pawls are on?
    In the picture below...see the blue bearing seal? Your spacer is probably stuck to it.


  15. #15
    Senior Member garysol1's Avatar
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    Worse case call Zipp. There tech guys are very very helpful.

  16. #16
    Senior Member garysol1's Avatar
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    Take a look HERE. This covers all years....

  17. #17
    Carpe Diem bdcheung's Avatar
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    ok, so presumably if my old (202P) freehub still works fine, then the washer must still be attached to the cassette body. Now, as I'm looking at the PDF diagram, I still don't understand where the washer is: inside the cassette body or just stuck to the back of it?
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  18. #18
    Carpe Diem bdcheung's Avatar
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    btw, thanks for your help gary
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  19. #19
    Carpe Diem bdcheung's Avatar
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    Quote Originally Posted by garysol1 View Post
    In the picture below...see the blue bearing seal? Your spacer is probably stuck to it.

    ooook, that makes sense. I didn't check for a washer covering the bearing seal. I'll look there tonight when I get home.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  20. #20
    Isaias NoRacer's Avatar
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    I have two wheels that have freehub bodies like the one I attached. They have a rubber seal in the area indicated but no spacer at the bearing.

    The one that Gary shows (blue body) doesn't have the same lip.
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    2009 mileage = 14,738 miles; 2010 mileage = 15,234 miles; 2011 mileage = 17,344 miles; 2012 mileage = 11,414 miles; 2013 = 12,169

  21. #21
    Carpe Diem bdcheung's Avatar
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    No rubber seal on my old 202P, but there is a rubber seal on the hub shell that presses against the area indicated in your picture.

    Come to think of it, my cassette body doesn't look anything like the one gary posted - both bearings are inside the cassette body, separated by the axle sleeve. I really don't think there's a washer but will take pics and post them tonight.
    Last edited by bdcheung; 05-28-08 at 08:25 AM.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
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  22. #22
    Carpe Diem bdcheung's Avatar
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    This is what my (old) cassette body looks like:


    The new one looks like this:


    I have no idea where the washer would go.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
    ΛΧΑ ΔΞ179 - 15% off your first Hammer Nutrition order!

  23. #23
    Isaias NoRacer's Avatar
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    Quote Originally Posted by bdcheung View Post
    This is what my (old) cassette body looks like:


    The new one looks like this:


    I have no idea where the washer would go.
    There's an extra step in the new body.
    2009 mileage = 14,738 miles; 2010 mileage = 15,234 miles; 2011 mileage = 17,344 miles; 2012 mileage = 11,414 miles; 2013 = 12,169

  24. #24
    Carpe Diem bdcheung's Avatar
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    Quote Originally Posted by NoRacer View Post
    There's an extra step in the new body.
    What effect does that have? The two bodies are supposed to be interchangeable, I thought.
    "When you are chewing the bars at the business end of a 90 mile road race you really dont care what gear you have hanging from your bike so long as it works."
    ΛΧΑ ΔΞ179 - 15% off your first Hammer Nutrition order!

  25. #25
    Isaias NoRacer's Avatar
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    Quote Originally Posted by bdcheung View Post
    What effect does that have? The two bodies are supposed to be interchangeable, I thought.
    My -guess- is that the old body is 8, 9, 10 speed compatible and the new one, I believe, is for 10 speed only. The extra lip may give you extra length, causing it to push against something and causing the hub to bind.

    Also, the old one has cut-outs that line up with the flanges that keep the cogs in place. The new one doesn't have the same cut-outs. I wonder if the lip on the new one may be making contact with the hub body.

    I think we need a picture of the hub looking into the ratchet area of the hub.
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    2009 mileage = 14,738 miles; 2010 mileage = 15,234 miles; 2011 mileage = 17,344 miles; 2012 mileage = 11,414 miles; 2013 = 12,169

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