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Mangled Freehub Body; What Now

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4.1K views 9 replies 9 participants last post by  reptilezs  
#1 ·
Hi Everyone,

Bored waiting for a new derailleur hanger I decided to take my freehub body off to give it a clean. I have owned the bike for about a year, a 2018 Production Privee Shan N5, and it's overdue. Once I had the end caps off I realized I could hardly turn the axle and in a moment of clarity I realized why my back wheel wasn't spinning as freely as it should. I also found out the freehub would not come off, wouldn't even budge. I used a wooden block and a hammer to tap the axle back and forth a bit hoping to break the freehub loose. Eventually with a bit of tapping and a bit of WD40 I was able to free things up. I then threaded my cassette back on and gave it a yank and was able to get the freehub and axle out.

Whether from my tapping (probably) or some other evil force the freehub is, as you can see, destroyed. At this point I still cannot get the axle out. With the freehub and axle out I have tried tapping it through with a wooden block and hammer (and wet lube) and it moves but doesn't free up. In fact the bearing appears to be shaving metal off of the axle each time I have tapped it through. I am assuming the bearing is no longer round.

With the freehub destroyed I am ready to give up on the axle as well. The freehub is a Stan's Durasync (XD) on a Stan's Neo hub on a Stan's Flow MK3 rim. I am running a Sram 11 speed cassette. So my question is, what now? I'm not ready to build a new wheel so I am committed to the neo hub for the time being. Do I have to run a Stan's freehub body if I have a Stan's hub? Should I just order another durasync and axle and be done with it or are there other options? If so, how does one confirm compatibility?

This is my first time diving this far into a wheel and I'd greatly appreciate any feedback.

1933122
 
#3 ·
This is a classic failure mode of, what I call, a fabulous freewheel. Essentially - in spite of being "a freehub" it actually is kinematically identical to a screw-on freewheel because of the length of axle sticking out and being unsupported, because lightweight.

You need parts for that specific hub, or one that this is an OEM of. New axle, shims, freehub sleeves and whatnots. In order to avoid this issue in the future - source a nice, stiff steel axle for your bike. Which is going to be hard, because steel axles are a niche item to say the least.
 
#4 ·
You can rebuild it, but in the end you will have the same hub with the same design that led to that failure.

Lacing a wheel isn't that hard. Lots of good you tube videos out there. If I were you I would find decent new hub and relace it to the existing rim - assuming you like the rim. Or have a reputable shop do it if you can get their time to work on it. You can get a hope pro 4 or DT Swiss 350 for about $225 if you shop around. Lot's of other brands if you don't like those options.
 
#6 ·
Thanks everyone. Yes, the more I think about it and the more I read about Stan's hubs the less I want to be committed to this setup. Will do some research tonight. I'd really love to build a new wheel, but always had it as more of a winter project. The derailleur hanger failure that provided the time for this investigation threw the chain into the wheel and slightly bent a couple spokes. Might as well replace them all. Just frustrated, that was my first ride after waiting three weeks for bike yoke dropper parts from Germany. Now I'm waiting for a derailleur hanger from Andorra, and soon will be waiting for wheel parts from not sure where yet!

Thanks again for everyone's feedback!