S197 Cortex cambered axle stud replacement

[Badger]

Two of the studs got damaged in transport and have to be replaced.
Getting hold of Cortex can be extremely random and I am currently waiting for an answer once again.
With the weekend ahead I am placing the question here.

The studs neither come out nor go in even when removing the front cover (as I was advised). Unfortunately the ABS ring is in the way and does not allow for the needed clearance.

I am looking for information on how to go about it and how far the axle needs to be taken apart. There are a lot of parts in it and the less that has to be disassembled the better as work to this extend this was not expected or planned for.

 

[Badger]

Before anyone asks, the schematics do not show or mention the ABS ring.

Copy of ffr-4001-302s_instructions.pdf

drive.google.com

 

[navseng]

Probably easiest to just remove the hub and then either unscrew or remove the abs ring (press fit?). Then a stud swap should be easy!
It appears they have a bearing spacer between the bearings to set the preload on the bearings so that's nice! Should be easy. Not a bads thing to familiarize yourself with these parts and keep an eye on the bearings anyways.

 

[blacksheep-1]

Looks like it got dropped at the shippers.. nice.

 

[captdistraction]

since you're there, mind measuring out a stud? I'm curious what it would take to convert it to M14 studs

 

[Badger]

Filip from Cortex and the TMO community hopped on and we got it all figured out. Some work is involved but in hindsight and lots of new knowledge its really not that bad.

If you did not assemble the axle yourself it looks quite daunting, thus I am supplementing a write up to help with that.
YMMV but it should give you a head start. For any specific questions Cortex should be contacted directly.

In order to install the studs, the tone ring will have to be moved. A blowtorch will help with it, but tabs from rubber mallet might be needed. It might be very tricky to move the ring back into place.

IMO the easiest way is to take the hub off and reassembled it. Luckily this is only 7 tiny bolts and a single big one.

Before you start, make sure you have this tool at hand:

and RTFM:

Copy of ffr-4001-302s_instructions.pdf

drive.google.com

Disassembly

1. Use your usual method to loosen the studs you want to replace.
2. Remove bolts 16
3. Pull off 15. Be prepared to catch the bearings 18. They might stick on for a bit but eventually fall out. Be careful to not miss the O-ring between 15 and 11.
4. Pull out the camber axle 17. Center it while pulling to no scar any other parts with the axles teeth on the far end.
5. Remove bolts 14 and ring 13. Take some pictures on where the bolts were placed.
6. To loosen the spindle nut 12 use the tool that came with the axle. The driver side has backwards threads and unscrews clockwise! This nut gets torqued with 160 ft/lb and it takes some force to remove it.
7. After that everything comes apart by pulling out the hub.
8. Use a blowtorch to heat up the ABS tone ring (not in the diagram) and remove it.

Assembly

1. Insert studs to the hub.
2. Place Hub in the freezer for a couple hours. (@navseng made this suggestion and it works beautifully)
3. Put the ABS tone ring in the even for 10 mins at ~400F.
4. The tone ring should now drop back onto the hub purely by gravity without any force needed whatsoever.
5. Wait till everything settles and temperatures even out.
6. Assemble everything in reverse order. Some bearing grease might be needed.
7. Torque spindle nut to 160 ft/lb
8. Snug the small bolts up, but don't over tighten them.
9. Use your usual procedures to pull the last bit into the hub.