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Possible to rebuild a DT440 rear hub without specialist tools?

big-ted

big-ted

Danced with A, attacked by C, fired by D.
Sep 27, 2005
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As title. The user's manual makes reference to several specialist tools. Most of these look like they could be substituted for appropriately-sized sockets but it looks as though one needs to remove the star-ratchet, which seems like there's no getting around the need for the appropriate tool. I need to replace all the bearings. Anyone offer any advice?
 
M

marshalolson

Turbo Monkey
May 25, 2006
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super easy.

rubber mallet a few sockets, and a bolt/nut/washers to press everything back together.
 
big-ted

big-ted

Danced with A, attacked by C, fired by D.
Sep 27, 2005
1,400
47
Vancouver, BC
...and another question! The diagram shows just the two bearings. Is there really no bearings in the freehub to worry about?!

440rear_hub.jpg
 
Udi

Udi

RM Chief Ornithologist
Mar 14, 2005
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It's been a long time since I owned these, but if I remember correctly you can't remove the drive-side main hub bearing without removing part #5, which requires a special tool. It also takes a lot of force to unscrew because it tightens in the drive direction. It's a terrible design.

However this was on a Hugi FR, I never had to change bearings on the 440 I had. I am not sure what marshalolson did, but unless they changed the design (which would be good), that bearing is not coming out any other way.

A friend of mine made me the tool by welding a metal extension (with wrench flat) to an old star ratchet.
 
al-irl

al-irl

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Dec 9, 2004
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even with the specialist tool it can be difficult to get part #5 out. As you pedal its constantly being tightened. Ive had the special tool disintegrate while trying to remove part #5. So have had to just leave that bearing and replace the rest.
 
mattmatt86

mattmatt86

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Feb 9, 2005
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I rebuilt my 440s last year, only thing I couldn't do at home was remove the ring drive piece everyone is talking about. I took it to a local shop and they charged 20 bucks to remove it and put it back in after I installed new bearings. I bought a set of Ceramic Bearings on Ebay for 70 bucks for both the front and rear hubs.
 
M

marshalolson

Turbo Monkey
May 25, 2006
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Udi said:
I am not sure what marshalolson did, but unless they changed the design (which would be good), that bearing is not coming out any other way.
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gha. good point, i was mistakenly thinking i pressed the drive side out the disc side - but you are correct, you need a ring drive tool. the shop i worked at did the same thing: old star ratchet tack-welded to an extension.

however a little pb-catalyst and a long cheater bar really helps get that sucker out of the hubshell.
 
big-ted

big-ted

Danced with A, attacked by C, fired by D.
Sep 27, 2005
1,400
47
Vancouver, BC
Ugh. Kind of what I feared. I have to say, I'm not enthralled with this hub. The standard ratchet doesn't give fantastic engagement, the bearings have never run particularly smoothly, they require specialist tools to work on, and they're bloody expensive to boot. Just a shame they came with the stock build on my bike.
 
big-ted

big-ted

Danced with A, attacked by C, fired by D.
Sep 27, 2005
1,400
47
Vancouver, BC
Sweet. Hopefully this thread gets more views now the peanut gallery have arrived! :)

FYI, we've established this ain't happening without the tools. I just need to know the bearing sizes in the freehub.
 
gemini2k

gemini2k

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Jul 31, 2005
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big-ted said:
Sweet. Hopefully this thread gets more views now the peanut gallery have arrived! :)

FYI, we've established this ain't happening without the tools. I just need to know the bearing sizes in the freehub.
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I just ordered the tools yesterday. I'll go at mine sometime this week or next and post my findings.
 
kidwoo

kidwoo

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Aug 25, 2003
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big-ted said:
Sweet. Hopefully this thread gets more views now the peanut gallery have arrived! :)

FYI, we've established this ain't happening without the tools. I just need to know the bearing sizes in the freehub.
Click to expand...
Just be sure you get the tools.

There are some specialized tools you're going to need.

I don't think it's possible without the right tools.




For those thinking you need new bearings based on them dragging, the end caps on the rotor side sometimes just get pressed in to far on the axle. I was thinking the same thing last night (because I HAVE crushed an axle in one of these before). I just pulled the cap off and reinstalled it and it's all freewheelin n' shlt now.
 
'size

'size

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May 30, 2007
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Udi

Udi

RM Chief Ornithologist
Mar 14, 2005
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I think you have all the tools you need now, right here in this thread.
 
big-ted

big-ted

Danced with A, attacked by C, fired by D.
Sep 27, 2005
1,400
47
Vancouver, BC
So, on the off-chance anyone still cares, it is indeed two 6902rs bearings in the freehub. I guess that's a kind of a redeeming feature in that both front and rear hubs use 6902 (or 61902 in North American codes) throughout...
 
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