Originally Posted by newbojeff
Actually his exact word was that the freehub was "toast."
Not to get too defensive, but I don't think I used too much grease. Using a 10 cc syringe, I put a layer down before the bearings, then a layer over the bearing. Also, in riding it with bad slippage for the last 2 days I realized it has probably been slipping on gear changes for months.
Maybe it was toast, but I'll try to be judicious with the grease in the future.
Sounds like you did the overhaul just fine. I personally use a LOT more grease than that, and have never had a problem. I pack it in until it's practically oozing out the sides of the hub. But the freehubs I have overhauled are all Shimano, and the placement of the main axle bearings relative to the freehub bearings are likely different from those in the Bontrager hubs.
It's unfortunate that Bontrager hubs need an 11 mm allen wrench
Shimano hubs use a 10mm which is the largest size that comes standard with a bike-specific kit. I think they may a patent on it or something ridiculous like that.
But I'm glad to know that Bontrager freehubs can be replaced at reasonable cost!!