Cassette won't fit on freewheel any mo bizarre!

Hi,

I took a 9S 105 13-23 cassette off my Ultegra 10S hub and I couldn't fit it
back on any more. I tried a new 9S Ultegra and a new 105 casette and these
fit like a glove on the same freehub.

I can't figure out why the fairly new cassette I removed won't slide all the
way over the freehub. I see no anormalities inside the cogs and the
cassette is clean.

Any ideas?

Gr, Derk

Derk wrote:
Hi,

I took a 9S 105 13-23 cassette off my Ultegra 10S hub and I couldn't fit it
back on any more. I tried a new 9S Ultegra and a new 105 casette and these
fit like a glove on the same freehub.

I can't figure out why the fairly new cassette I removed won't slide all the
way over the freehub. I see no anormalities inside the cogs and the
cassette is clean.

Any ideas?

Gr, Derk

I don't know about your hub, but I had this problem once with a freehub
body made of aluminum. The steel cassette created small notches in the
soft freehub body. Filing them down solved the problem.

Using aluminum for that part had no real advantage save perhaps some
negligible weight decrease, so from then on I've only bought hubs which
use steel there.

Stephen Greenwood wrote:

I don't know about your hub, but I had this problem once with a freehub
body made of aluminum.
It's a nearly new hub. It's absolutely undamaged. The only cassette that
won't fit is the one I took off yesterday. All other cassettes that I have
here fit without a problem....

The steel cassette created small notches in the
soft freehub body. Filing them down solved the problem.
I know that can happen, but this hub is undamaged.

Using aluminum for that part had no real advantage save perhaps some
negligible weight decrease
Just like frames! :-)

Greets, Derk

Derk wrote:
Stephen Greenwood wrote:

I don't know about your hub, but I had this problem once with a freehub
body made of aluminum.
It's a nearly new hub. It's absolutely undamaged. The only cassette that
won't fit is the one I took off yesterday. All other cassettes that I have
here fit without a problem....

The steel cassette created small notches in the
soft freehub body. Filing them down solved the problem.
I know that can happen, but this hub is undamaged.

So if the *only* cassette that won't fit on your freehub is that one
steel cassette, have you inspected it? Maybe you some how damaged the
cassette. Alternatively, have you tried mounting that cassette onto
another freehub body?

Cassettes are relatively cheap, they're consumables, so if that one
particular cassette doesn't fit, use another.

On 6 Oct 2006 13:23:42 -0700, "bfd" wrote:


Derk wrote:
Stephen Greenwood wrote:

I don't know about your hub, but I had this problem once with a freehub
body made of aluminum.
It's a nearly new hub. It's absolutely undamaged. The only cassette that
won't fit is the one I took off yesterday. All other cassettes that I have
here fit without a problem....

The steel cassette created small notches in the
soft freehub body. Filing them down solved the problem.
I know that can happen, but this hub is undamaged.

So if the *only* cassette that won't fit on your freehub is that one
steel cassette, have you inspected it? Maybe you some how damaged the
cassette. Alternatively, have you tried mounting that cassette onto
another freehub body?

Cassettes are relatively cheap, they're consumables, so if that one
particular cassette doesn't fit, use another.

Dear BFD,

True, other cassettes work, so the problem is easily solved.

But how the hell do you damage a reasonably new cassette so that it
won't fit back over the hub?

If someone like me had posted the question, dismissing it would be
quite sensible. My first thought was to ask if Derk had tried putting
the cassette on upside-down to see if it would fit part-way on, but
luckily it occurred to me that the spline pattern is asymmetrical and
the idea would never work, so no one will know just how dumb I--

Anyway, Derk strikes me as a fairly competent poster when it comes to
such matters, so I'm very curious to know what happened. If such
things can happen to posters like him, it will be good for posters
like me to learn painlessly how to avoid it.

Somehow I doubt that Derk took the cassette apart and reassembled all
the cogs and reassembled them bottom-side up. (I once put the front
wheels back on a Dodge army ambulance with the dishing outward instead
of inward, so I'm more alert to such mistakes than posters of normal
intelligence.)

I liked Stephen's idea of hard steel notching soft aluminum, but Derk
replied that this isn't the problem.

Cheers,

Carl Fogel

Derk wrote:

I don't see any damage on the inside of the cassette. I tried to take it
apart, but I can't fit a hex wrench to open the cogs that are fixed
together with 3 tiny hex bolts.......

Invest in a proper (eg PB) set of hex keys then. In all probability one
of the cogs has shifted slightly (to fit in a detent of the too soft
aluminium hubbody you had it previously fitted too)) causing it not to
fit on a properly designed and machined freehub
--
---
Marten Gerritsen

INFOapestaartjeM-GINEERINGpuntNL
www.m-gineering.nl

wrote:

I liked Stephen's idea of hard steel notching soft aluminum, but Derk
replied that this isn't the problem.
I have one theory, but I don't know if it makes any sence: I put that
cassette from my "new" DT Wheelset on an older CXP33 wheelset. I used to
put loose 8 speed cogs on that freewheel hub and that one has notches
caused by the loose cogs.

After that one ride I decided I preferred to put that cassette back on the
DT freewheel. Could it be possible that during that one ride, during which
I did interval training, the "new" cassette was deformed by the notches of
the old freewheel?
I don't see any damage on the inside of the cassette. I tried to take it
apart, but I can't fit a hex wrench to open the cogs that are fixed
together with 3 tiny hex bolts.......

Gr, Derk

M-gineering wrote:

Invest in a proper (eg PB) set of hex keys then.
I have a set of Parktool hex wrenches.....

In all probability one
of the cogs has shifted slightly (to fit in a detent of the too soft
aluminium hubbody you had it previously fitted too)) causing it not to
fit on a properly designed and machined freehub
I think so too.

Gr, Derk

Marten wrote:
In all probability one of the cogs has shifted slightly

MArten was right! I just found another tiny hex wrench that fits. I unscred
the hex bolts slightly and it now fits on the freehub body again.

I am amazed one 55 km ride with the cassette on a slightly dented freehub
was enough to cause 1 cog to shift slightly, whilst it is part of a cog
package that's held together with 3 hexscrews.

Thanks!

Derk

On Sat, 07 Oct 2006 12:45:00 +0200, Derk wrote:

Marten wrote:
In all probability one of the cogs has shifted slightly

MArten was right! I just found another tiny hex wrench that fits. I unscred
the hex bolts slightly and it now fits on the freehub body again.

I am amazed one 55 km ride with the cassette on a slightly dented freehub
was enough to cause 1 cog to shift slightly, whilst it is part of a cog
package that's held together with 3 hexscrews.

Thanks!

Derk

Dear Derk,

I'm still puzzled.

Unless it was the outermost cog that shifted, how could you pull the
cassette off the original hub?

That is, if one or more cogs had twisted out of alignment with the
others by biting into the aluminum hub to different depths, shouldn't
that have prevented the whole cassette from pulling straight off the
hub? They would have formed a very short version of a screw.

Cheers,

Carl Fogel