THREE PAWL HUBSTECHNICAL MANUAL
V2020.09

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

How to use the manual................................................................................................ 4

1.7

General Maintenance Information............................................................................... 4

1.8

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

1.9

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

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

2. MAINTENANCE OF THE REAR HUB WITH THREE PAWL SYSTEM........................ 5
2.1

Service intervals........................................................................................................... 52.2

Overview........................................................................................................................ 52.3

Required tools............................................................................................................... 62.4

Required wearing parts and materials........................................................................ 6

2.5

Remove end caps, freewheel body and spacer........................................................... 72.6

Removing pawls, pawl spring and dust seal............................................................... 8

2.7

Dismounting the ring nut............................................................................................. 92.8

Dismounting the ball bearing...................................................................................... 102.9Cleaning and checking all parts.................................................................................. 11

2.10 Mounting the ball bearing at the drive side................................................................. 12
2.11 Mounting the ring nut................................................................................................... 13
2.12 Mounting the bearing on the non drive side................................................................ 14
2.13 Mounting pawls, pawl spring and dust seal................................................................ 16
2.14 Attaching the spacer, the freewheel body and the end caps...................................... 17
2.15 Check the functionality................................................................................................. 19

3. TROUBLE SHOOTING................................................................................................ 202

1. GENERAL
1.1 VALIDITY
This manual describes the component specified on the front page and the footer. This manual is valid for thedesign of the product as of 21.09.20. Deviations are possible and all items are subject to technical 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.

NOTICE… 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.
Any warranty claims will lapse if work is not carried out properly.

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. The DT Swiss contact details can be found on the back. 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 HOW TO USE THE 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 seals
requires mild cleaners. Observe the instructions for use of the respective cleaner.
DT Swiss recommends the following cleaners:•••

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 "Requiredmaterial".
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 condition of the tools are perfect. Always keep thetools in their original packaging or adequate devices to prevent damage.

SPARE PARTS
Only original or DT Swiss approved spare parts may be used.

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 wrongly maintained or installedcomponents. If you have doubts, please contact your region's DT Swiss pro level service center.

1.10 WARRANTY
Warranty conditions, see www.dtswiss.com

42. MAINTENANCE OF THE REAR HUB WITH THREE PAWL SYSTEM
2.1 SERVICE INTERVALS
TaskInterval

Replacing the pawls and pawl spring

Under normal operating conditions: 12 months

Cleaning and greasing the freewheel system

In case of extreme operating conditions (regular rides
in dust, rain, snow, or in case of frequent transport
while raining) 3 months

Replacing the ball bearingsin case of malfunctions(see “3. Trouble Shooting“ on page 19)

Replacing the spacer

in case of malfunctions(see “3. Trouble Shooting“ on page 19)

Replacing the dust seal

in case of wear and tear or damage

2.2 OVERVIEW
725

8

6

4

12

3
11
9

10

1

end cap non drive side5

ring nut

9pawl spring

2ball bearing

6spacer

10

pawl

3axle

7

freewheel body11

dust seal4

hub shell

8

end cap drive side

Three Pawl Hubs - Technical Manual52.3 REQUIRED TOOLSTools

Specification

Quantity

Article number

installation cylinder Ø15 x 28 x 35 mm

2

HXTXXX00N5024S

tool for ring nut

1

HXTXXX00N5266S

plastic hammer

12.4 REQUIRED WEARING PARTS AND MATERIALS
Wearing parts / Materials

Specification

Quantity

Article number

DT Swiss universal grease(only required if service kit 3 Pawl is not used)

20 g

HXTXXX00NMG20S

ball bearing Ø15 x 28 x 7 mm

2

HSBXXX00N1468S

ring nut M34 x1

1

HCDXXX00N6137S

spacer steel 10.1 mm

1

HCDXXX00S4190S

dust seal

1

HSOXXX00N4083S

1

HWTXXX00NSK3PS

service kit 3 Pawl system, consisting of:6•

3x pawl•

1x pawl spring•

DT Swiss universal grease2.5 REMOVE END CAPS, FREEWHEEL BODY AND SPACER
1. Clamp the right end cap into a vice.
2. Pull off the wheel, respectively the hub.
→ Make sure that the freewheel body does not
fall off when pulling off.
3. Clamp the left end cap into a vice.
4. Pull off the wheel, respectively the hub.

5. Remove the freewheel body from the hub.

6. Pull the spacer off the axle.

Three Pawl Hubs - Technical Manual72.6 REMOVING PAWLS, PAWL SPRING AND DUST SEAL
1. Remove the pawl spring with a small screwdriver.
2. Remove the pawls.

3.

8

Remove the dust seal.

2.7 DISMOUNTING THE RING NUT
The ring nut must only be removed if it is damaged or if the ball bearing at the drive side has to be replaced.
Due to the torque acting on the ring nut during pedaling, the ring tightens while riding. We recommend
loosening the ring nut only when the wheel is complete as the lever is much larger.
1. Clamp the ring nut tool into a vice in the highposition.
2. Push the drive side of the hub onto the tool.
3. Turn the hub counterclockwise.

4. Remove the ring nut from the tool.
5. Remove the tool from the vice.

Three Pawl Hubs - Technical Manual92.8 DISMOUNTING THE BALL BEARINGThe ball bearings only need to be dismounted if there is a malfunction.
1. Tap out the ball bearing on the non drive side witha plastic hammer.

2. Remove the bearing from the axle.

3. Turn the axle 180° and insert it through the huband ball bearing on the drive side.
4. Tap out the ball bearing on the drive side.

5. Remove the bearing from the axle.

10

2.9 CLEANING AND CHECKING ALL PARTS
1. Clean and check all parts of the hub.
•Check the ring nut for wear and damages.

•Check the dust seal for damages.

•Check the spacer.

2. Replace damaged or worn parts.
3. Disassembled ball bearings should be replaced.

Three Pawl Hubs - Technical Manual112.10 MOUNTING THE BALL BEARING AT THE DRIVE SIDE
1. Grease the bearing seat and the thread for thering nut with universal grease.

2. Put the installation cylinder into the vice.
3. Insert the axle into the installation cylinder withthe long side down.
4. Push the hub shell onto the installation cylinder
with the drive side facing upwards.
5. Push a new bearing onto the axle with the coloredside facing outwards.

6. Push the second installation cylinder onto the nondrive side of the hub shell.
7. Carefully tap the ball bearing into the hub shellwith a plastic hammer.
8. Remove the hub shell from the installation
cylinder.
9. Remove the installation cylinder from the vice.

12

2.11 MOUNTING THE RING NUT
1. Clamp the ring nut tool in the deep position in thevice.
2. Slide the ring nut onto the tool with thechamfered side down.

3. Insert the axle with the long side down throughthe ring nut tool.
4. Push on the hub shell.

5. Push the installation cylinder from above onto thehub shell.
→ The use of the installation cylinder prevents
the ring nut from jamming during screwing in.

6. Screw in the ring nut approx. 2 turns.
To avoid damages to the hub shell, the ring nut mustnot be screwed into the hub shell by more than
2 turns while the ring nut tool is clamped in the deep
position in the vice!

Three Pawl Hubs - Technical Manual13

7. Unclamp the ring nut tool, turn it 90° and clamp itback into the vice in the high position.
8. Place the hub shell with the ring nut back on thetool and tighten the ring nut by hand as tight aspossible.

2.12 MOUNTING THE BEARING ON THE NON DRIVE SIDE
1. Grease the bearing seat on the non drive side withuniversal grease.

2. Clamp the ring nut tool in the high position in thevice.
3. Push the hub shell onto the ring nut tool.

14

4. Insert the axle with the long side first through thehub shell into the ring nut tool.

5. Put on a new bearing on the non drive side withthe colored side facing outwards.

6. Put the installation cylinder onto the bearing.
7. Tap in the ball bearing with a plastic hammer.

8. Check the play of the hub. To do this, hold the axle
firmly and move the hub axially.
→ The hub must not have any play!
→ If play is noticeable, tap in the ball bearing on
the non drive side.
9. Check the running of the ball bearings. To do this,hold the axle firmly and turn the hub shell.
→ The hub must turn smoothly.
→ If the hub runs stiffly, tap out the ball bearing
on the non drive side and reassemble it.

Three Pawl Hubs - Technical Manual152.13 MOUNTING PAWLS, PAWL SPRING AND DUST SEAL
1. Put on the dust seal.

2.

Slightly grease the freewheel body and the dust
seal with universal grease.

3. Attach the pawls.

4. Attach the pawl spring.
→ The open end of the spring must be
positioned at the pin.

16

2.14 ATTACHING THE SPACER, THE FREEWHEEL BODY AND THE END CAPS
1. Grease the ring nut with universal grease.

2.

Slightly grease the axle with universal grease andslide the spacer onto the axle.

3. Push the freewheel body onto the hub with aslight turning movement.
4.

Check whether the freewheel body can be turned
and the pawls engage.

5.

Grease the exposed hub sides and inside of bothend caps.

Three Pawl Hubs - Technical Manual

176. Put on both end caps by hand.
Caution: The shorter end cap must be placed on thedrive side.

2.15 CHECK THE FUNCTIONALITY
1. Turn the freewheel body in both directions.
→ The freewheel body can be turned
counterclockwise easily.
The pawls engage audibly and perceptibly.
→ The freewheel body cannot be turned
clockwise.
2. Check 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.

Spacer was compressed byovertightening the thru axle.

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

Pawls are mounted
incorrectly.

Check correct assembly.

Too much or wrong grease on
the pawls.

Clean and grease pawls.

Pawls are worn out.

Replace pawls.

Ring nut is damaged.

Replace ring nut.

Ball bearings were notmounted correctly.

Check correct assembly.

Ball bearings are worn out.

Replace ball bearings.

Ball bearings are worn out.

Replace ball bearings.

Ball bearing non drive side
too tight.

Check correct assembly.

Freewheel does not engage/ slips

Hub has axial play

Hub rotates stiffly

Mounting sequence of the ballbearings not observed.
Hub makes noise

Ball bearings are worn out.

Notches from the cassetteon the freewheel body.

The steel cassette works itself Remove bad notches from theinto the aluminium web of the rotor using a file.
freewheel body.

Freewheel body rotates with Ball bearings in the freewheel
difficulty.
body are worn out.
Freewheel is too noisy / tooquiet.

Replace ball bearings.

Replace freewheel body.

The perception of the freewheel sound is very subjective. Whilesome riders prefer a loud freewheel sound, other riders wanta quiet freewheel. In principle, the freewheeling sound can be
influenced by the amount of grease on the pawls. Less grease
increases the freewheeling sound, but at the same time leads tohigher wear. Too much grease can cause the freewheel to stick.

Three Pawl Hubs - Technical Manual19

DT SWISS AG
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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.
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USA - Grand Junction, CO 81505info.us@dtswiss.com

DT SWISS DEUTSCHLAND GmbH
Pixeler Strasse 56
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Germany
info.de@dtswiss.com

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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
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