SRAM Zipp 76/176, Service Manual

Page 1: ...GEN 0000000004927 Rev E 2020 SRAM LLC 77 177 76 176 Hubs s e r v i c e m a n u a l ...

Page 2: ...nty does not apply to products that have been incorrectly installed adjusted and or maintained according to the respective SRAM user manual The SRAM user manuals can be found online at sram com service This warranty does not apply to damage to the product caused by a crash impact abuse of the product non compliance with manufacturer s specifications of intended usage or any other circumstances in ...

Page 3: ...R HUB BEARING REMOVAL 9 REAR HUB BEARING INSTALLATION 11 DRIVER BODY INSTALLATION 13 END CAP INSTALLATION 14 FRONT HUB SERVICE 15 TOOLS NEEDED FOR SERVICE 15 REPLACEMENT PARTS 15 FRONT HUB EXPLODED VIEW 76D 16 FRONT HUB END CAPS 76D 16 FRONT HUB EXPLODED VIEW 77D 17 FRONT HUB END CAPS 77D 17 FRONT HUB EXPLODED VIEW 77 76 77 PICTURED 18 FRONT HUB END CAPS 77 76 18 FRONT HUB BEARING REMOVAL 19 FRONT...

Page 4: ...SAFETY FIRST We care about YOU Please always wear your safety glasses and protective gloves when servicing Zipp products Protect yourself Wear your safety gear ...

Page 5: ... Zipp Parts Zipp 61903 176 177 hub bearings x2 Zipp 176 177 driver body seal and shim kit Zipp 176 177 driver body kit optional Common Tools Sealed bearing puller with 17 mm slotted attachment 17 mm ID over axle bearing spacer min length of 50 mm 17 mm x2 ID over axle bearing spacers min length of 9 mm Wheels Manufacturing Press 1 Sealed Bearing Press Kit or similar 6903 61903 bearing press adapte...

Page 6: ...76D R e a r H u b E x p l o d e d V i e w 1 7 6 D R e a r H u b E n d C a p s 1 7 6 D Quick Release 12 mm x 142 mm Drive Side Non Drive Side Driver Body Driver Body Seal Shim Disc Brake Hub Shell 61903 Bearing 61903 Bearing Axle ...

Page 7: ...a r H u b E x p l o d e d V i e w 1 7 7 D R e a r H u b E n d C a p s 1 7 7 D Quick Release 12 mm x 142 mm 12 mm x 135 mm Drive Side Non Drive Side Driver Body Driver Body Seal Disc Brake Hub Shell Shim 61903 Bearing 61903 Bearing Axle ...

Page 8: ...ured R e a r H u b E x p l o d e d V i e w 1 7 7 1 7 6 1 7 7 P i c t u r e d R e a r H u b E n d C a p s 1 7 7 1 7 6 Quick Release Drive Side Non Drive Side Shim Driver Body Driver Body Seal Rim Brake Hub Shell 61903 Bearing 61903 Bearing Axle ...

Page 9: ... quick release skewer into one side of the hub and use the skewer to push the opposite end cap off the hub Repeat to remove the other end cap Position the wheel horizontally with the driver body facing downward This will allow the pawls and leaf springs to remain in the driver body as it is being removed Use your fingers to remove the driver body assembly from the hub shell N OTI C E A shim rests ...

Page 10: ...nd usage information consult your bearing puller manufacturer s instructions Thread the shaft of the bearing puller into the slotted attachment Hold the wheel firmly in place and forcefully pull back on the slide hammer to remove the bearing from the non drive side of the hub shell Remove the bearing from the slotted attachment Spray isopropyl alcohol on the rear hub bearing bores and the axle and...

Page 11: ...e threaded rod of the bearing press tool Insert the threaded rod through the drive side of the hub shell and position the narrow end of the bearing adapter into the center of the bearing Slide the second 6903 bearing adapter onto the threaded rod and position the adapter into the non drive side hub shell bearing bore Thread the bearing press handle onto the threaded rod Turn the threaded handle cl...

Page 12: ...ing into the non drive side bearing bore until it is hand tight Check for side to side axle movement in the hub If there is movement repeat step 5 to press the bearings into the hub shell further Remove the bearing press tool N OTI C E Do not overtighten the bearing The over axle bearing spacers must be long enough so there is no compression on the axle as the second bearing is being pressed into ...

Page 13: ...ort section of www zipp com Install the seal with the groove on the seal facing away from the driver body midway over the pawls so that they stay compressed Slide the driver body assembly ratchet side first into the drive side of the hub shell Use a cable tie to push the rubber driver body seal into the groove in the drive side of the hub shell NOTICE Do not scratch the hub shell Ensure the seal i...

Page 14: ...hol on a rag and clean the axle and end caps Install the quick release or thru axle end caps by pressing the end caps onto the axle of the hub by hand N OTI C E Ensure the o ring is in the groove on the internal surface of the end cap Ensure there is no grease on the o ring or internal surface of the end cap or axle Grease may cause the end caps to move This concludes the service for Zipp 177D 176...

Page 15: ... zipp com T o o l s N e e d e d f o r S e r v i c e Zipp Parts Zipp 61803 76 77 hub bearings x2 Zipp 61903 76D 77D hub bearings x2 Common Tools Aluminum vise blocks Bench vise Clean lint free shop towels Grease brush Nitrile gloves Plastic mallet Safety glasses 17 mm x2 ID over axle bearing spacers min length of 9 mm Wheels Manufacturing Press 1 Sealed Bearing Press Kit or similar 2 6903 Bearing p...

Page 16: ... Exploded View 76D F r o n t H u b E x p l o d e d V i e w 7 6 D F r o n t H u b E n d C a p s 7 6 D Quick Release 15 mm x 100 mm 12 mm x 100 mm Drive Side Non Drive Side Axle Hub Shell 61903 Bearing 61903 Bearing ...

Page 17: ...17 Front Hub Exploded View 77D F r o n t H u b E x p l o d e d V i e w 7 7 D F r o n t H u b E n d C a p s 7 7 D Quick Release 15 mm x 100 mm 12 mm x 100 mm Axle 61903 Bearing Hub Shell 61903 Bearing ...

Page 18: ...Front Hub Exploded View 77 76 77 Pictured F r o n t H u b E x p l o d e d V i e w 7 7 7 6 7 7 P i c t u r e d F r o n t H u b E n d C a p s 7 7 7 6 Quick Release Axle 61803 Bearing Hub Shell 61803 Bearing ...

Page 19: ...ter of the end cap into the vise blocks and pull up on the hub to remove the end cap Repeat on the other side to remove the other end cap Alternate method To remove quick release end caps insert a quick release skewer into one side of the hub and use the skewer to push the opposite end cap off the hub Repeat to remove the other end cap Use a plastic mallet to gently tap the exposed axle end on the...

Page 20: ...d usage information consult your bearing puller manufacturer s instructions Thread the shaft of the bearing puller into the slotted attachment Hold the wheel firmly in place and forcefully pull back on the slide hammer to remove the bearing from the non drive side of the hub shell Remove the bearing from the slotted attachment Spray isopropyl alcohol in the front hub bearing bores and axle and cle...

Page 21: ...ring adapter onto the threaded rod of the bearing press tool Insert the threaded rod through the non drive side of the hub shell and position the narrow end of the bearing adapter into the center of the bearing Slide the second bearing adapter onto the threaded rod and position the adapter into the drive side hub shell bearing bore Thread the bearing press handle onto the threaded rod Turn the thr...

Page 22: ...hrough the drive side of the front hub and through the non drive side bearing Install a new bearing over the axle into the drive side bearing bore of the front hub with the orange seal facing outward 5 3 4 Drive side 6903 Bearing Drive side 6803 Bearing ...

Page 23: ...ress handle onto the threaded rod Turn the threaded handle clockwise to press the bearing into the drive side bearing bore until it is hand tight Check for side to side axle movement in the hub If there is movement repeat step 5 to press the bearings into the hub shell further Remove the bearing press tool N OTI C E Do not overtighten the bearing The over axle bearing spacers must be long enough s...

Page 24: ...ropyl alcohol on a rag and clean the axle and end caps Install the quick release or thru axle end caps by pressing the end caps onto the axle of the hub by hand N OTI C E Ensure the o ring is in the groove on the internal surface of the end cap Ensure there is no grease on the o ring or internal surface of the end cap or axle Grease may cause the end caps to move This concludes service for Zipp 77...

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