RATCHET EXP HUBSCONVERSION OF THE RATCHETS FROM 36 TO 54 TEETH
V2020.10

1. GENERAL.................................................................................................................. 3
1.1

Validity........................................................................................................................... 3

1.2

Safety............................................................................................................................ 3

1.3

Target group.................................................................................................................. 3

1.4

Layout............................................................................................................................ 3

1.5

DT Swiss manual concept............................................................................................ 3

1.6

Using this manual........................................................................................................ 4

1.7

General maintenance information............................................................................... 4

1.8

Environmental protection............................................................................................. 4

1.9

Exclusion of liability...................................................................................................... 4

1.10 Warranty........................................................................................................................ 4

2. CONVERSION OF THE RATCHETS FROM 36 TO 54 TEETH..................................... 52.1

Overview........................................................................................................................ 52.2

Required tools............................................................................................................... 62.3

Conversion kit for 180 hub........................................................................................... 72.4

Conversion kit for 240 hub........................................................................................... 82.5

Removing end caps, freewheel body and freewheel system...................................... 92.6

Dismounting the ball bearing on the non drive side................................................... 102.7

Dismounting the 36 teeth threaded ratchet................................................................ 112.8

Pressing the ball bearing into the threaded 54 teeth ratchet.................................... 122.9Screwing the 54 teeth threaded ratchet with the bearing into the hub shell............ 122.10 Mounting the ball bearing at the non drive side......................................................... 142.11 Mounting the freewheel system.................................................................................. 16
2.12 Putting on the freewheel body and the end caps........................................................ 18
2.13 Check the functionality................................................................................................. 183. TROUBLE SHOOTING................................................................................................ 192

1. GENERAL
1.1 VALIDITY
This manual describes the component specified on the front page and the footer. It is valid for theconstruction level of the component on the 07.10.20. Deviations are possible and all items are subject totechnical changes.

1.2 SAFETY
The safety instructions are classified as follows:

DANGER...indicates a hazardous situation that, if not avoided, will result in death or serious injury.

CAUTION… indicates a hazard with a medium level of risk which, if not avoided, may result in minor or moderate
injury.

NOTE… indicates a potentially hazardous situation that may result in damage to property.

1.3 TARGET GROUP
This manual is intended for the user of the component and dealers. This manual offers the experienced user
the possibility to carry out minor service work himself. If you have any doubts about your own abilities, youshould definitely contact a specialist or a DT Swiss Service Center. If the work is not carried out properly, any
warranty claims expire.

1.4 LAYOUT
The cover page and the footing provide information about the type of product and manual as well as theversion of the manual. On the back you will find the DT Swiss contact details. A list of all DT Swiss service
centers can be found at www.dtswiss.com.
This manual is intended for being printed as an A5 booklet. Only print this manual if electronic usage is notpossible.

1.5 DT SWISS MANUAL CONCEPTThe DT Swiss manuals are split into the following types of manuals:••

User Manual: Information for the end user on how to install and use the component.
Technical Manual Detailed information for the end user and the dealer on how to maintain thecomponent, spare parts and technical data.

Ratchet EXP - Technical Manual31.6 USING THIS MANUALThe steps described in this manual must be carried out in the order they are shown. If steps are ignored or
executed in a wrong order, the function of the component cannot be guaranteed.

1.7 GENERAL MAINTENANCE INFORMATION
Unless otherwise specified, moving parts, threads, O-rings and seals must be greased before assembly.

CLEANING
For an optimal result of the maintenance works, every component that will be disassembled must be cleaned.
Only use cleaners which do not damage the components. Especially the cleaning of O-rings and sealings
requires mild cleaners. Observe the instructions for use of the respective cleaning agent.
DT Swiss recommends the following cleaning products:•••

Motorex Rex
Motorex Swissclean
Motorex OPAL 2400, 3000 OPAL, OPAL 5000

Use soap water or similar mild cleaners for external cleaning.

TOOLS
To ensure a damage-free mounting and dismounting of the components, only use the tools which arementioned in this manual. Special tools are indicated at the beginning of a chapter in the table "Requiredtools".
The use of different tools is at the discretion of the user. If components are damaged by the usage of differing
tools, the user is liable.
DT Swiss special tools are precision tools. Damage-free mounting and dismounting of the components canonly be ensured if the tools are working properly and if the conditions of the tools are perfect Always keep thetools in their original packaging or adequate devices to save them from damages.

1.8 ENVIRONMENTAL PROTECTION
The statutory regulations shall apply. Whenever possible, avoid creating waste. Waste, especially carbon,lubricants, cleaners and any other fluids must be disposed in an environmentally compatible manner.
Only print this manual if electronic usage is not possible.

1.9 EXCLUSION OF LIABILITY
The activities listed in this manual may only be carried out by persons with sufficient specialist knowledge.
The user is liable for any damage or consequential damage caused by wrong maintained or wrong installedcomponents. If you have doubts, please contact your allocated DT Swiss pro level service center.

1.10 WARRANTY
Warranty conditions, see www.dtswiss.com

42. CONVERSION OF THE RATCHETS FROM 36 TO 54 TEETH
2.1 OVERVIEW

546789101112

13

31

2

1

end cap non drive side

8spacer2
3ball bearing non drive side9loose ratchet

axle

10

spring4

hub shell

11

washer5ball bearing drive side12

freewheel body6

threaded ratchet13

end cap drive side

7

sealing

Ratchet EXP - Ratchet Conversion

5

2.2 REQUIRED TOOLSTools

Quantity

Article number

1HWTXXX00N2544S

installation cylinder Ø15 x 24 x 60 mm(only required for ball bearings on the nondrive side with 180 hubs)

1

HXTXXX00N5025S

installation cylinder Ø15 x 26 x 40 mm

1HXTXXX00N5314S

mounting / dismounting tool for thethreaded ratchet

1

HXTXXX00N8387S

mounting / dismounting tool ball bearing
drive side1

HXTXXX00N6106S

tool kit*, consisting of:Specification* The tool kit can be purchased as a complete set or the included tools can be purchased separately.

6

2.3 CONVERSION KIT FOR 180 HUB
Description

Specification

Quantity

DT Swiss special grease

1ball bearing 6802 Ø15 x 24 x 5 mm

1ball bearing 1526 Ø15 x 26 x 7 mm

1threaded ratchet 54 teeth

1loose ratchet 54 teeth

1spring

1washer

1Ratchet EXP - Ratchet Conversion

Article number

HWYXXX00N2534S

7

2.4 CONVERSION KIT FOR 240 HUB
Description

Specification

Quantity

DT Swiss special grease

1ball bearing 1526 Ø15 x 26 x 7 mm2threaded ratchet 54 teeth

1Article number

HWYXXX00N2543S

8loose ratchet 54 teeth

1spring

1washer12.5 REMOVING END CAPS, FREEWHEEL BODY AND FREEWHEEL SYSTEM
1. Pull off both end caps by hand.
If the end caps cannot be pulled off by hand, clamp
the end caps carefully into a vice with groundclamping jaws and pull the hub / wheel upwards.

2. Pull the freewheel body off the hub.

3. Pull the spacer off the axle.

Ratchet EXP - Ratchet Conversion

9

4. Remove the ratchet the washer and the springfrom the freewheel body.

2.6 DISMOUNTING THE BALL BEARING ON THE NON DRIVE SIDETo ensure correct bearing clearance, the ball bearing at the non drive side must also be removed.
1. Tap out the ball bearing on the non drive side witha plastic hammer with slight hammer strokes
onto the axle.

2.

10

Remove the ball bearing from the axle.

2.7 DISMOUNTING THE 36 TEETH THREADED RATCHET
Due to the torque which acts on the threaded ratchet during pedaling, the threaded ratchet tightens duringriding. We recommend loosening the ratchet only when the wheel is complete as the lever is much larger.
1. Clamp the mounting / dismounting tool for thethreaded ratchet into the vice.
2. Fit the hub or wheel onto the tool in such a waythat the teeth of the tool engage in the teeth of
the threaded ratchet.
3. Insert the axle into the hub and through thethreaded ratchet.

HXTXXX00N8387S

4. Push the installation cylinder onto the non driveside of the hub.
5. Loosen and screw off the ratchet by turning thehub counterclockwise.
6. Remove the hub from the tool.

HXTXXX00N5314S/
HXTXXX00N5025S

7. Remove the ratchet with the ball bearing.
The threaded 36T ratchet and the pressed-in ballbearing are no longer needed in the further course of
the conversion process.

Ratchet EXP - Ratchet Conversion

112.8 PRESSING THE BALL BEARING INTO THE THREADED 54 TEETH RATCHET
1. Slightly grease the contact surface of the newball bearing and the 54 teeth threaded ratchet.
2. Put the threaded ratchet with the toothing facing
downwards onto the mounting / dismounting
tool.
→ Put the ratchet on the side of the tool withthe fitting diameter. The ratchet may only
move minimally in the tool.

HXTXXX00N6106S

3. Put a new ball bearing with the colored side
facing downwards onto the ratchet.

4.

Carefully press the bearing into the ratchet with light hammer strokes on the outer ring of the ball bearing
until the bearing protrudes 1 to 2 mm beyond the ratchet.
→ The ball bearing must not be pressed further into the ratchet.

2.9 SCREWING THE 54 TEETH THREADED RATCHET WITH THE BEARING INTO THE HUB
SHELL
1. Slightly grease the threaded ratchet and the thread of the hub shell with universal grease.
2. Put the mounting tool into the vice.
3. Insert the axle into the installation cylinder withthe short side first.

4. Push the hub shell onto the installation cylinder
with the drive side facing upwards.

121-2 mm5. Slide the threaded ratchet with the ball bearing
onto the axle.
→ The toothing of the threaded ratchet must
face upwards.

6. Push the mounting tool into the toothing of theratchet and screw the ratchet into the hub shellby a few turns with light pressure.
→ Before the ratchet engages in the thread of
the hub shell, it must be pushed over thesealing with a little pressure.
→ While screwing in, make sure that the ratchet
is screwed in straight and does not cant!
→ It must be possible to screw in the ratchetwithout effort until a high resistance iscreated. Now the ball bearing is in contact
with the hub shell and the ratchet must be
brought into the end position with greater
force. Continue with next step.
7. Remove the mounting tool, remove the hub from the installation cylinder and unclamp the installation
cylinder from the vice.
8. Clamp the mounting / dismounting tool for thethreaded ratchet into the vice.
9. Slide the axle with its long end through the ballbearing.
10. Put the hub / the wheel with the mounted ratchet
onto the mounting tool.

Ratchet EXP - Ratchet Conversion

1311. Push the installation cylinder onto the non driveside of the hub.
→ By using the axle and the installation cylinder,
the hub shell is guided when the ratchet isscrewed on. The ratchet cannot cant.
12. Tighten the threaded ratchet as tight as possible
by turning the hub clockwise by hand.

HXTXXX00N5314S /HXTXXX00N5025S

13. Remove the hub from the mounting / dismounting tool and put the tool out of the vice.

2.10 MOUNTING THE BALL BEARING AT THE NON DRIVE SIDE
1. Make sure that the axle is in the hub with the longside first.
2. Grease the bearing seat and the axle withuniversal grease.

3.

14

Push a new bearing on the axle with the coloredside facing outwards.

4. Clamp the mounting / dismounting tool for thethreaded ratchet into the vice.
5. Put the hub on the tool in the vice.
6. Put the installation cylinder onto the bearing.
7. Tap in the ball bearing carefully with slighthammer strokes.
HXTXXX00N5314S /HXTXXX00N5025S

HXTXXX00N8387S

8. Check the ball bearings.
→ It must be possible to turn the hub with slightresistance.
→ The hub must not have axial play.
9. Tap the ball bearing on the non drive side in or out
and repeat previous steps until the hub is turningsmoothly.

Ratchet EXP - Ratchet Conversion

15

2.11 MOUNTING THE FREEWHEEL SYSTEMDANGER
RISK OF INJURY DUE TO LIMITED FREEWHEEL FUNCTION DUE TO INCORRECTLUBRICATION!
If too much grease is applied on the ratchets, the actuation of the ratchets may not work. The ratchets may
slip during pedaling.
••

Only apply a thin, even layer of grease.
Only use the red DT Swiss special grease.

1. Apply DT Swiss special grease evenly to the outerand the inner toothing of the ratchets using a finebrush.
→ For an optimal functionality of the freewheelsystem, a thin layer of grease is sufficient.

2. Put the spacer onto the axle.

16

3. Put the spring onto the washer and put theratchet o to the spring.

4. Put the washer, spring, and ratchet into thefreewheel body.

Ratchet EXP - Ratchet Conversion

17

2.12 PUTTING ON THE FREEWHEEL BODY AND THE END CAPS
1. Put the freewheel body onto the hub.
2. Check if the freewheel body can be turned and if
the ratchets are engaging.

3.

Grease both ball bearings and the inside of theend caps with universal grease.

4. Put on the left and the right end cap.
→ The shorter end cap must be placed on thedrive side.

2.13 CHECK THE FUNCTIONALITY
1. Turn the freewheel body in both directions.
→ The freewheel body can be turned
counterclockwise easily.
The ratchets engage audibly and perceptibly.
→ The freewheel body cannot be turned
clockwise.
2. Check the tightness of the end caps.
→ The end caps are firmly seated on the axle
and are fully pushed on.

18

3. TROUBLE SHOOTING
Issue

ReasonSolution

Freewheel is blocked

Spacer was forgotten duringassembly.

Check correct assembly,
see “2.1 Overview”, page 5.

Spacer was compressed byovertightening the thru axle.

Measure the length of the spacer. If
the spacer is shorter than 10.7 mm, it
must be replaced.

Loose ratchet is mounted upsidedown.

Check correct assembly,
see “2.1 Overview”, page 5.

Too much or wrong grease on theratchets.

Clean and grease ratchets,
see “2.11 Mounting the freewheelsystem”, page 16.

Ratchets are worn.

Replace ratchets.

Spring was forgotten duringassembly.

Check correct assembly,
see “2.1 Overview”, page 5.

Ball bearings were not mounted
correctly.

Check correct assembly,
see “2.1 Overview”, page 5.

Ball bearings are worn out.

Replace ball bearings.

Ball bearings are worn out.

Replace ball bearings.

Ball bearing non drive side tootight.

Check correct assembly,
see “2.1 Overview”, page 5.

Freewheel does not engage /slips

Hub has axial play

Hub rotates stiffly

Mounting sequence of the ballbearings not observed.
Ball bearing pressed too far
into the threaded ratchet before
assembly.
Hub makes noise

Ball bearings are worn out.

Replace ball bearings.

Notches from the cassette on
the freewheel body.

The steel cassette works itself
into the alloy web of the freewheel
body.

Remove bad notches from the rotor
using a file.

Freewheel body rotates withdifficulty.

Ball bearings in the freewheel
body are worn out.

Replace freewheel body.

Freewheel is too noisy / tooquiet.

The perception of the freewheel sound is very subjective. While someriders prefer a loud freewheel sound, other riders want a quiet freewheel.
In principle, the freewheeling sound can be influenced by the amount ofgrease between the ratchets. Less grease increases the freewheelingsound, but at the same time leads to higher wear.

Ratchet EXP - Ratchet Conversion

19

DT SWISS AG
Längfeldweg 101
CH - 2504 Biel/Bienne
info.ch@dtswiss.com

DT SWISS ASIA LTD.
No.5, Jingke 5th Rd., Nantun District
Taichung City 408
Taiwan (R.O.C.)
info.tw@dtswiss.com

DT SWISS, INC.
2493 Industrial Blvd.
USA - Grand Junction, CO 81505
info.us@dtswiss.com

DT SWISS DEUTSCHLAND GmbH
Pixeler Strasse 56
D-33378 Rheda–Wiedenbrück
Germany
info.de@dtswiss.com

DT SWISS (FRANCE) S.A.S.
Parc d‘Activites de la Sarrée
Route de Gourdon
F - 06620 Le Bar sur Loup
info.fr@dtswiss.com

DT SWISS POLSKA Sp. z o.o.
ul. Towarowa 36
PL-64-600 Oborniki
Polandinfo.pl@dtswiss.com

Subject to technical alterations, errors and misprints excepted.
All rights reserved.
© by DT SWISS AG
www.dtswiss.com
HXD10000003773S