Thanks, Phantomcow2 and Luke. I'll make sure to check that damn bolt more regularly.

OrangeLeader, thanks for the info. I won't even try. I have no tools anyway. I'm in the middle of a bike tour in SE Asia and can't find any bearings that fit into this thing. My bearings are all smashed up too, the casing exploded and got grounded to bits. The bolt that held it all together must have fallen out and got lost on the road when the body fell off the spindle (the rubber end cap was still on the body).

It's amazing you've still got so much patience with Crank Bros. I would have looked around for something else.

Seems like they might have used cheap bearings or the design/manufacturing of the sealing mechanism might be poor so grits got in and accelerated the wear/failure of the bearings.

I've got a second pair at home. New eggbeaters with platforms around the body (on sale $50). If those go too, I'll say bye-bye to Crank Bros for good.

I guess I took the manufacturer's marketing blurb too literally: "Maintenance Free". When you're on a bike tour, you really want simple bomb-proof stuff. I like the eggbeaters simplicity alot so I'll give them another chance.

Thanks again for your help.