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PowerTap freehub cassette removal

DaveyLDaveyL Posts: 5,167
edited June 2010 in Workshop
I've got a PowerTap 2.4 SL with Shimano groupset. The first time I removed the cassette, I noticed that the splines on the freehub body had become notched by the individual cogs of the 105 cassette. This seems to be a common problem with the aluminium alloy freehub body. To combat this, I filed down the notches, and got some pins from American Classics, to hold the cogs together.

It's now been quite a while since I did this, but I've now come to try and change the cassette and I can't get the cassette off - it seems to be completely stuck. So I guess the pins haven't really helped, and now the cogs are probably well dug into the freehub body.

Anyone got any tips for getting the cassette off? Leveraging with a flat head screwdriver hasn't done the trick.
Le Blaireau (1)


  • pinkbikinipinkbikini Posts: 876
    I took mine into LBS the first time this happened - a vice and a rubber mallet seemed to do the trick. Last time I did a DIY bodge job - held the smallest cog with a chainwhip and tapped each of the cogs with a hammer. The (gentle) tapping seemed to be enough to loosen the cassette off the splines of the freehub. Don't overdo it...!
  • DaveyLDaveyL Posts: 5,167
    Thanks for the advice. I might just leave it to the LBS as I've asked them to order a steel freehub body as a replacement.
    Le Blaireau (1)
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