

To keep it short – patient is brand new Hope Pro 5 hub with XDR cassette drum. Wheels were built and hubs were serviced by a reputable shop on the other end of the country. Everything was supposed to be ready to ride.
I've mounted a cassette following Sram XDR manual. On the work stand everything was fine.
10km into the shakedown ride I've started to get bad shifting. Another 5 km or so later I've lost power and cassette started to turn both forward and backward without much resistance. At this point rapid uncontrolled disassembly of supposedly quality Hope hub was not yet apparent
I've started my walk of shame home and after few minutes pedals has started to turn as I walked my bike forward at this point I've noticed exposed freewheel pawls and blue grease inside of the hub.
Questions:
- can this be fixed? Can you give me any pointers how?
- Have my cassette and wheel install done this or the shop has messed up?
- how to prevent this from happening again? I got lucky riding close to home. My typical trips are into the woods far from potential help.
EDIT – Stuff I've verified:
- all parts that are supposed to be mounted according to hub exploded view and XD/XDR freehub exploded view are there
- I've removed cassette and disc rotor and measured OLD – Over Lock-nut Dimension to 148mm which is correct for my 148mm drops
- My hub dropouts measure to 149mm OLD which I guess is ok
- hub body says 148mm, freehub locking plate says XDR which is correct
EDIT 2: I've put everything back together but I still want to understand what is going on since it's just going to fail again if the fault is not addressed.
by InvestigatorSenior
4 Comments
You can probably just push the whole thing back in place and while slowly spinning it backwards. But that this happened during a ride implies that you may miss an endcap or some other component of the hub.
Should be an easy fix.
Remove the cassette and push the free hub body back into the hub while turning anti clockwise.
Then make sure the green seal is seated into the hub evenly all the way round. I usually use a tyre lever to push it on. If you have a large socket that will also work well.
Once the seal is in pull on the free hub body and it should remain in place.
Put cassette back on and ride.
I wonder if the outer bearing hasn’t been fitted to the freehub, or the wrong spacer fitted between the freehub and outer bearing. Here’s how its supposed to look
https://preview.redd.it/7u5ys4e36olg1.jpeg?width=700&format=pjpg&auto=webp&s=9cbdc4de7ecc293d9773bf50035041d9872a481e
Sometimes the rotate backwards does not work. If that doesn’t work, take a piece of dental floss, wrap it around all the pawls and pull tight so the loop closes all the pawls. Then the cascette body will drop into place, then just pull the waxed dental floss out.