Nukeproof generator rear hub maintenance and bearing replacement

Step 1. Remove the wheel from the bike. Take out the QR axle if you have the 135x9QR version. Remove the disk and the cassette from the hub and place apart.

Step 2. Unscrew the axle ends by hand or use a clamp. After removing one axle end, you can use a hex-tool inside the axle to hold it while unscrewing the opposite end.

Step 3. Slide the free-hub body out of the hub.

Step 4. Remove the dust rubber seals from both sides.

Step 5. Use a toothpick or a screwdriver to gently slide out the springs and the pawls.

Step 6. From the drive side, use a piece of wood to cover the axle and hit it with a hammer until it slides out to the other side.

Step 7. From the non-drive side, use a plastic or rubber screwdriver grip to cover the bearings and hit them until they slide out.

Step 8. Now you have the hub completely disassembled. Clean the hub body, springs, pawls, axle, seals, bearing spacer - washer. You can also replace the springs and pawls for new ones if you need or want to.

Step 9. Lube the hub body and the bearings to help them slide in. Place two new bearings in drive side, cover with one old bearing and press them with a hammer. To press the bearings you can use the old ones, a tube or a socket that perfectly sits in the outer bearing ring, like this 20mm socket in the photo.

Step 10. Lube the axle and slide it from the non-drive side. You can place the non-drive side bearing just to help centering and holding the axle.

Step 11. Press the non-drive side bearing and install the rubber seal with grease.

Step 12. On the drive side, put some thin/slick grease, not too much, in the springs and install them. Do the same to the pawls. (I use Rock&Roll super slick grease in this step, the same grease I use for bushings/seals in forks and shocks)

Step 13. Grease the rubber seal and install it. Install the washer to the a as it should be between the main body bearing and the free-hub. Grease the bearing side in the free hub body and put few drops of oil in the springs, pawls and engagement points. Clean any excess of grease or oil, sprigs and pawls should work and sound free.

Step 14. Slide in the free-hub body. At this point, rotate the free hub and check if sprigs and pawls sound clear and free. Screw the axle ends by hand or you can just give it a very little snug with a clamp.