I recently rebuilt a '99 Chorus rear hub, but I've had some problems getting the freehub to spin smoothly. I thought I had it adjusted correctly, or at least the best i could get it, but it didn't spin as freely as an NOS Record freehub of the same vintage. I was concerned, but nevertheless decided to build a wheel with it.

After initial tensioning and truing, I started to notice that the wheel was not truing correctly, and that areas that were once true, were suddenly out. I removed the wheel from the stand and realized that the freehub and axle were slightly loose! I suppose this caused some wobble and the wheel to appear out of true rather randomly.

When I tighten the drive-side 17mm locknut (left-hand threaded), the freehub snugs up, but then won't easily freewheel.

My question: Is there some order of operations to rebuilding and reinstalling the freehub that I am missing? I believe I have reassembled everything in the hub correctly. I used Phil grease, but not too much. Thanks.

99 was a change year for these hubs, so this advice her applies to those with the aluminum axle, The steel axle hubs are similar but not identical.

The freehub and wheelhub on these are supported independently of each other on the axle, with the only connection being the ratchet mechanism. The adjustment of the freehub therefore should not have affected the wheel in any way.

Best bet, deal with the issues one at a time by removing the freehub entirely, and correctly adjusting the hub from the left side. If it won't adjust predictably, check that you didn't accidentally put ball one too many in either race. Once adjusted, build the wheel.

The freehub should simply drop on and be tightened, there is no adjustment. If it's too tight it's possible that you're missing a spacer, or the freehub bearings themselves are stiff.

If you have the older steel axle hubs, I believe the process is similar, but it's been a while since I serviced on of these, so I'm not 100% sure.

Thanks. This makes sense. It is the AL axle hub.