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Old 09-02-08, 11:03 AM   #1
smd3
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Cassette jammed on freehub

I have a Niner S.I.R.9 with a WTB laserdisc lite rear hub. I have managed to dig the splines of the SRAM cassette in to the splines of the hub. Does anyone have any suggestions on removing it? It'd be nice if I could salvage these parts.

Worse case, I start saving for a set of wheels for the Niner, I guess they could use an upgrade anyway.
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Old 09-02-08, 11:14 AM   #2
Sturmcrow
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Do you have any way to hold the freehub body still while turning the cassette backwards with a chainwhip? That could possibly undig the splines from the body and allow you to pull it off. You may be able to get a visegrips on the part of the freehub that sticks out past the cassette.
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Old 09-02-08, 11:20 AM   #3
mp123
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I've found a small screwdriver wedged between the teeth of the cogs can be used to carefully pry them back counterclockwise one at a time.

You'll also want a metal file to smooth out the splines on the freewheel which will be a little messed up where the cogs dug in.

This is a very common problem with light alloy cassette carriers, I've always been able to salvage things by working carefully.
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Old 09-02-08, 11:39 AM   #4
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I had this problem with new light wheel with soft alloy (light) freehub.

Undo lockring in normal fashion,
remove cogs to extent possible ie until you get to jammed cog
Using 2 chain whips, one applied normally on the cog with most teeth eg 23-27
put 2nd chainwhip on the cog that has dug into the freewheel
it usually budges, some gentle tapping with small peen hammer may help

<edit> and clean rough edges on freewheel with small file as mp says
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