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help: i break rear freehub bodies regularly...

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Cycling Equipment
Published
8 May 2003
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14 May 2003
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Bigfaceworm
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  1. All,

    I'm a hobbyist mountain biker (road too). I weigh 250# and am 6'4", with strong legs.

    I regularly break the freehub bodies when I ride in Moab Utah on the slickrock surfaces there.
    (I go once a year for vacation.) I generally break them while climbing the short 20-30% grades
    in a low gear.

    Each of the past two years I've broken the freehub body on two consecutive days (thankfully Poison
    Spider bike shop warrantied the part both times). The freehubs I've broken are Shimano XT/LX/other.

    My current count is 8 freehub bodies in the past 5 years.

    I'm tired of breaking them and am looking for another solution.

    Phil Wood gets high praise, but they do have the same basic design (pawls) - and that's a bit
    worrisome. Chris King has their RingDrive(tm) - which sounds cool, but nobody else has that design
    and I worry about that.

    I generally ride single track and dirt roads, with the annual trip to Moab. No big drops for me,
    just lots of climbing.

    Any help?

    thanks,

    BFW

  2. "bigfaceworm" <[email hidden]> wrote in message
    "]news:[email hidden]...

    Quoted message said:

    I weigh 250# and am 6'4", with strong legs. I regularly break the freehub bodies The freehubs I've
    broken are Shimano XT/LX/other. I'm tired of breaking them and am looking for another solution.

    Quoted message said:

    Chris King has their RingDrive(tm) - which sounds cool, but nobody else has that design and I
    worry about that.

    Call Chris King and tell them your story: The King hub is probably your answer; but let them tell
    you if a King hub is for you or not. They're reputed to be bombproof; but most people don't destroy
    freehubs like you do, so maybe they're not made for that kind of abuse.

    Another possibility is a Shimano Silent Clutch hub. It uses a centrifugal clutch instead of pawls.
    Might be stronger - might not be. I just know it's different from the other Shimano freehubs.

    Wish I had a definite answer for you; but I suggest that you call the manufacturers and try to talk
    with an engineer or at least a knowledgeable product rep. Surely you're not the first guy who has
    destroyed freehub bodies with such frequency.

    BTW: Ever thought about racing? :-)

    Best of luck,

    Barry

  3. "bigfaceworm" <[email hidden]> wrote in message
    "]news:[email hidden]...

    Quoted message said:

    I regularly break the freehub bodies when I ride in Moab Utah on the slickrock surfaces there. (I
    go once a year for vacation.) I generally break them while climbing the short 20-30% grades in a
    low gear.

    What part of the assembly, specifically, are you breaking?

    --
    ==================
    Kraig Willett www.biketechreview.com
    ==================

  4. "Kraig Willett" <[email hidden]> wrote in message
    news:<[email hidden]>...

    Quoted message said:

    What part of the assembly, specifically, are you breaking?

    I believe I am breaking the pawls, though I've always let the shop do the work and not examined the
    part myself.

    They symptoms are:
    - loud snap sound when it happens
    - the inability to glide - i must continuously pedal or the chain will wind up.
    - inability to pedal hard - pedalling hard results in more noise and the pedals just spinning (the
    back wheel doesn't rotate)

  5. "bigfaceworm" <[email hidden]> wrote in message
    "]news:[email hidden]...

    Quoted message said:

    "Kraig Willett" <[email hidden]> wrote in message


    news:<[email hidden]>...

    Quoted message said:
    Quoted message said:

    What part of the assembly, specifically, are you breaking?

    I believe I am breaking the pawls, though I've always let the shop do the work and not examined
    the part myself.

    They symptoms are:
    - loud snap sound when it happens
    - the inability to glide - i must continuously pedal or the chain will wind up.
    - inability to pedal hard - pedalling hard results in more noise and the pedals just spinning (the
    back wheel doesn't rotate)

    Your failures puzzle me a bit. I have laboratory tested wheels that use the LX hub at around 2500 -
    3000 in-lb of torque (extremely large) and that produced a failure of the aluminum spline on the
    hubshell itself (IIRC, after 10,000 cycles or so) - the freehub did not fail.

    I have also longitudinally cracked other shimano steel freehub shells using very similar test
    protocols. Of the 30 or so wheels that I tested, I didn't observe a pawl failure. This is why I am a
    bit puzzled.

    Anybody else produce shimano pawl failures?

    --
    ==================
    Kraig Willett www.biketechreview.com
    ==================

  6. Quoted message said:
    Quoted message said:

    "Kraig Willett" <[email hidden]> wrote in message


    news:<[email hidden]>...

    Quoted message said:
    Quoted message said:

    What part of the assembly, specifically, are you breaking?

    Quoted message said:

    "bigfaceworm" <[email hidden]> wrote in message
    "]news:[email hidden]...

    Quoted message said:

    I believe I am breaking the pawls, though I've always let the shop do the work and not examined
    the part myself.

    They symptoms are:
    - loud snap sound when it happens
    - the inability to glide - i must continuously pedal or the chain will wind up.
    - inability to pedal hard - pedalling hard results in more noise and the pedals just spinning
    (the back wheel doesn't rotate)

    "Kraig Willett" <[email hidden]> wrote in message
    "]news:[email hidden]...

    Quoted message said:

    Your failures puzzle me a bit. I have laboratory tested wheels that use


    the

    Quoted message said:

    LX hub at around 2500 - 3000 in-lb of torque (extremely large) and that produced a failure of
    the aluminum spline on the hubshell itself (IIRC, after 10,000 cycles or so) - the freehub did
    not fail.

    I have also longitudinally cracked other shimano steel freehub shells


    using

    Quoted message said:

    very similar test protocols. Of the 30 or so wheels that I tested, I


    didn't

    Quoted message said:

    observe a pawl failure. This is why I am a bit puzzled.

    Anybody else produce shimano pawl failures?

    Yes. We see them but not in any consistent pattern. Large riders with daily commute climbs and small
    riders in infrequent use. The failure is normally a broken pawl, not the outer case of the cassette
    body. And this is not an epidemic - ten or a dozen per year out of a lot of service. I haven't lost
    one on one of my own bikes but we sell relatively small numbers of midprice Shimano cassette
    equipped bicycles.

    I agree it sounds astronomically implausible that one rider would find several defective Shimano
    cassette bodies in a series. But I can't postulate a scenario that would cause such a repeatable
    failure either - they are pretty tough and dependable overall, especially within their price range.
    He does accurately describe a pawl failure.
    --
    Andrew "stumped" Muzi yellowjersey.orgyellowjersey.org Open every day since 1 April 1971

  7. In article said:

    I agree it sounds astronomically implausible that one rider would find several defective Shimano
    cassette bodies in a series.

    Maybe if successive cassette bodies were being bought from the same shop, and if that shop was
    selling from a batch bought at one time, and if that batch had a manufacturing defect?

    --
    Ned Mantei Department of Cell Biology, Swiss Federal Institute of Technology CH-8093 Zurich,
    Switzerland

  8. Ned Mantei <[email hidden]> wrote in message
    news:<[email hidden]>...

    Quoted message said:

    Maybe if successive cassette bodies were being bought from the same shop, and if that shop was
    selling from a batch bought at one time, and if that batch had a manufacturing defect?

    Unfortunately, that wasn't the case: In 2003, the first one to break was installed in 2002 (at shop
    in Moab) the second was the replacement installed in 2003 (at shop in Moab)

    In 2002, the first one to break was on a brand new wheel from Oregon the second was installed at the
    shop in Moab

    In earlier years they were from a variety of shops...

    The shop in Moab says they regularly replace anywhere from 2-4 freehub bodies A DAY! during peak
    mountain biking season. And that's just one of the 5(?) shops in Moab.

    Oddly, my brother (same weight, same riding style) has been using the same wheel (and freehub body)
    for 5 years now, riding the same rides. No breakage...

    I have changed the freehub shell two times, so I didn't think it was the problem. But perhaps
    there's some problem with the shell and the way it interacts with the pawls...

  9. Ned Mantei said:
    In article said:

    I agree it sounds astronomically implausible that one rider would find several defective Shimano
    cassette bodies in a series.

    Maybe if successive cassette bodies were being bought from the same shop, and if that shop was
    selling from a batch bought at one time, and if that batch had a manufacturing defect?

    My guess is that the rider with all the failures is somehow injecting grease into the freehub to
    lube it. This will prevent the pawls from fully seating , so it's not that difficult to damage them
    one at a time until they all fail catastrophically.

    Either that or he's insanely strong, immensely heavy, or supremely unlucky. ;-)

    Mark Hickey Habanero Cycles habcycles.comhabcycles.com Home of the $695 ti frame

  10. how about the gearing? 250 lbs. on something like 22/32 is allot of torque just an idea

  11. "A Muzi" <[email hidden]> wrote...

    Quoted message said:

    I agree it sounds astronomically implausible that one rider would find several defective Shimano
    cassette bodies in a series. But I can't postulate a scenario that would cause such a repeatable
    failure either - they are pretty tough and dependable overall, especially within their price
    range. He does accurately describe a pawl failure.

    I used to break freehubs at the pawls pretty often (a few times a year) and still break one every
    year or so. I think the mechanism is that you start with a partial engagement which slips and leads
    to the pawls slamming into the next engagement point really hard and failing.

    I ride a lot in the winter (thickens up the lube so the pawls don't engage as quickly or completely)
    and do a lot of trials stuff (sudden pedal kicks when the hub isn't really engaged) and I think that
    leads to my problems. I've gotten better at being smoother and making sure the hub is engaged before
    pedalling and it helps some.

    Trials guys love the Chris King hubs and a lot of them used the LX silent clutch (? do they still
    make that) and both of them apparently stand up better than the Shimano hubs to this kind of thing.

    - Marty G

  12. --------------090208060808050402010104 Content-Type: text/plain; charset=us-ascii; format=flowed
    Content-Transfer-Encoding: 7bit

    Marty Gulaian said:

    "A Muzi" <[email hidden]> wrote...

    Quoted message said:

    I agree it sounds astronomically implausible that one rider would find several defective Shimano
    cassette bodies in a series. But I can't postulate a scenario that would cause such a repeatable
    failure either - they are pretty tough and dependable overall, especially within their price
    range. He does accurately describe a pawl failure.

    I used to break freehubs at the pawls pretty often (a few times a year) and still break one every
    year or so. I think the mechanism is that you start with a partial engagement which slips and leads
    to the pawls slamming into the next engagement point really hard and failing.

    I ride a lot in the winter (thickens up the lube so the pawls don't engage as quickly or
    completely) and do a lot of trials stuff (sudden pedal kicks when the hub isn't really engaged) and
    I think that leads to my problems. I've gotten better at being smoother and making sure the hub is
    engaged before pedalling and it helps some.

    Trials guys love the Chris King hubs and a lot of them used the LX silent clutch (? do they still
    make that) and both of them apparently stand up better than the Shimano hubs to this kind of thing.

    - Marty G


    I second that. I had a pawl failure and it was after I'd acquired a dumb habit of pedalling with one
    leg, through a very smal arc. The jerky motion resulted in a repeated shock impact on the pawls
    rather than a simple load carrying. I didn't think much about it until after the failure. Is there
    something about the user's riding style on these trails that results in these kind of "pedal kicks"
    and pawl impacts? He claims his brother has the same riding style but perhaps there is a difference
    in the smoothness and acceleration of the pedals before the pawl engagement.

    --------------090208060808050402010104 Content-Type: text/html; charset=us-ascii
    Content-Transfer-Encoding: 7bit

    <!DOCTYPE html PUBLIC "-//W3C//DTD HTML 4.01 Transitional//EN"> <html> <head> <title></title>
    </head> <body> <br> <br> Marty Gulaian wrote:<br> <blockquote type="cite"
    cite="[email hidden]"> <pre wrap="">"A Muzi" <a
    class="moz-txt-link-rfc2396E" href=""][email hidden]"><[email hidden]></a>
    wrote... </pre> <blockquote type="cite"> <pre wrap="">I agree it sounds astronomically implausible
    that one rider would find several defective Shimano cassette bodies in a series. But I can't
    postulate a scenario that would cause such a repeatable failure either - they are pretty tough and
    dependable overall, especially within their price range. He does accurately describe a pawl failure.
    </pre> </blockquote> <pre wrap=""><!----> I used to break freehubs at the pawls pretty often (a few
    times a year) and still break one every year or so. I think the mechanism is that you start with a
    partial engagement which slips and leads to the pawls slamming into the next engagement point really
    hard and failing.

    I ride a lot in the winter (thickens up the lube so the pawls don't engage as quickly or completely)
    and do a lot of trials stuff (sudden pedal kicks when the hub isn't really engaged) and I think that
    leads to my problems. I've gotten better at being smoother and making sure the hub is engaged before
    pedalling and it helps some.

    Trials guys love the Chris King hubs and a lot of them used the LX silent clutch (? do they still
    make that) and both of them apparently stand up better than the Shimano hubs to this kind of thing.

    - Marty G </pre> </blockquote> I second that. I had a pawl failure and it was after I'd
    acquired a dumb habit of pedalling with one leg, through a very smal arc. The jerky motion
    resulted in a repeated shock impact on the pawls rather than a simple load carrying. I
    didn't think much about it until after the failure. Is there something about the user's
    riding style on these trails that results in these kind of "pedal kicks" and pawl impacts?
    He claims his brother has the same riding style but perhaps there is a difference in the
    smoothness and acceleration of the pedals before the pawl engagement.<br> </body> </html>

    --------------090208060808050402010104--

  13. John Albergo <[email hidden]> wrote in message news:<[email hidden]>...

    Quoted message said:

    I second that. I had a pawl failure and it was after I'd acquired a dumb habit of pedalling with
    one leg, through a very smal arc. The jerky motion resulted in a repeated shock impact on the
    pawls rather than a simple load carrying. I didn't think much about it until after the failure. Is
    there something about the user's riding style on these trails that results in these kind of "pedal
    kicks" and pawl impacts? He claims his brother has the same riding style but perhaps there is a
    difference in the smoothness and acceleration of the pedals before the pawl engagement.

    I'd like to think my pedaling is somewhat smooth, but...

    I'm definitely not slamming down on the pedal suddenly. If memory serves me right, the breaks
    generally happen in the middle (well end) of the short & steep climbs. So, the hub should already be
    engaged. But I probably pedal more piston- like than a smooth circle.

    Someone commented on my injecting grease that might foul up the pawl action. I would hope that the
    bike shops installed the hubs w/the correct amount of lubrication. I can say that I personally
    didn't inject any grease b/c I'm kind of lazy about hub maintenance.

    I don't remember the gearing ratio - it's a pretty standard triple ring up front and 9 speed in the
    back. Lots of torque.

    Lastly, I've broken the Shimano silent hub mechanism also. In that case, the shop was unable to
    extract the freehub body and had to replace the whole thing (I got a new wheel).

  14. (bigfaceworm) said:

    I'd like to think my pedaling is somewhat smooth, but...

    I'm definitely not slamming down on the pedal suddenly. If memory serves me right, the breaks
    generally happen in the middle (well end) of the short & steep climbs. So, the hub should already
    be engaged. But I probably pedal more piston- like than a smooth circle.

    I've seen people with such choppy spins that they actually "freewheel" for a split second with the
    pedals at 12 and 6 o'clock. If so, the pawls would have to re-engage twice every crank revolution..
    effectively putting the rear hub through an accelerated life testing process (getting the equivalent
    of many years of "normal riding" during a few steep hills).

    Quoted message said:

    Someone commented on my injecting grease that might foul up the pawl action. I would hope that the
    bike shops installed the hubs w/the correct amount of lubrication. I can say that I personally
    didn't inject any grease b/c I'm kind of lazy about hub maintenance.

    That was my suggestion - lots o' folks have messed up their pawls with grease, but it doesn't sound
    like your problem now.

    Quoted message said:

    I don't remember the gearing ratio - it's a pretty standard triple ring up front and 9 speed in the
    back. Lots of torque.

    Lastly, I've broken the Shimano silent hub mechanism also. In that case, the shop was unable to
    extract the freehub body and had to replace the whole thing (I got a new wheel).

    Whatever it is you're doing - cut it out!!! ;-)

    Mark Hickey Habanero Cycles habcycles.comhabcycles.com Home of the $695 ti frame

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