WoB- Yes I see the clearance/preload of cartridge bearings close up on installation (or better to say when a "bad" bearing is felt "in situ" then removed, the "badness" feel reduces as the preload loosens up). As to the growth of the actual rolling elements with heat- I suspect that the tolerances of a bike exceed any tiny heat induced changes. So I tend to look for the greater effect. Is the bearing seat (axle or shell machining) within x number of microns? Was the bearing pressed in with the same accuracy? Are the bearing's inner and outer races in the same plane, or is there a slight offset (preload) between them that's not designed into the bearing by the bearing manufacturer? (As in the shell sleeve and the spindle don't have the correct bearing seat spreads). How much does the bending of the axle or distortion of the frame due to pedaling forces compare to heat induces growth? I don't know these answers but I have strong suspicions that the real life and setting of bike bearings are far more a factor then minor heat induced dimensional changes are.


This post started with the issue of noises/creaks/clicks/squeaks (and what each term is in real life has overlap that's different for each rider's perception). My experience with heavily preloaded bearings is not a short/quick/momentary type of sound if the bearings are otherwise in good shape and well lubed. I highly doubt that the rolling elements/races condition is causing the OP's noises. A good condition bearing poorly installed, loose fitted, dry seats can very well cause the noise the OP mentions.


Example is a hub I worked on just Friday, a cartridge bearinged design with an Al shell and axle. The complaint was a noise similar to what I suspect the OP was trying to describe (and again the same noise will be described differently by different people). With the freehub body removed and the axle in place one can feel the bearings slight roughness (they are tiny 6802s, these have very small diameter balls. The load capacity of the bearing is geometric with the ball diameter but linear with the ball count. No wonder the bearings are getting rough in a "short" time. They don't have the capacity of larger balled cartridges). I pulled the axle. Found that the axle has a snug but slip fit between the inner race and the axle bearing seat and that the non drive side seat was dry of any compound. I could see slight polishing of the axle seat that was uneven, suggesting the axle if moving within the inner race a tiny bit. This is what I attribute to be the cause of the noise. With the axle removed the bearing still in the shell felt rough. Removed both bearings and now the bearings feel not so bad, the preload of the shell press fit has been relieved. Reassembled with new bearings and HD marine grease between all seats/races. All feels smooth and no noise on test ride. If the sound returns and the bearings still feel good then I'll advance to a bit of 609 retaining compound on the axle seats. Andy.