Fault diagnosis chart for Sprinter 5-speed Hubs

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Jumping and self-changing gears :

1. Jumping in first gear
2. Jumping second gear
3. Jumping in third gear
4. Jumping in fourth gear
5. Jumping in fifth gear
6. Self changing between 1st and 2nd gear
7. Self changing between 1st and 3rd gear
8. Self changing between 4th and 5th gear
9. Self changing between high and low gears
10. Self changing between 2nd and 3rd gear
11. Self changing between 3rd and 4th gear

Other faults :

1. Hub runs stiffly, drags on pedals when free-wheeling.
2. No gears at all.
3. Sluggish gear change.

1. Jumping in first gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Deformed or weak planet cage circlip - Fit new circlip.
• Worn planet cage pawls - Replace pawls.
• Worn gear ring splines - Replace gear ring.
• Worn primary sun pinion - Replace primary sun pinion.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn driver pawls - Replace pawls.
• Incorrect right hand cone adjustment - Re-adjust the hub
• Worn clutch washer - Replace.

2. Jumping second gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Deformed or weak planet cage circlip - Fit new circlip.
• Worn planet cage pawls - Replace pawls.
• Worn gear ring splines - Replace gear ring.
• Worn primary sun pinion - Replace primary sun pinion.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn driver pawls - Replace pawls.
• Incorrect right hand cone adjustment - Re-adjust the hub
• Worn clutch washer - Replace.
• Ineffective clutch sleeve spring - Replace.
• Worn sun pinion spring - Replace.

3. Jumping in third gear

• Worn gear ring splines - Replace gear ring.
• Worn gear ring pawls - Replace pawls and springs.
• Weak or sticking gear ring pawl springs - Clean the hub, lubricate and/or replace pawl springs.
• Worn driver pawls - Replace pawls.
• Worn right hand ball ring ratchet teeth - Replace ball ring.
• Worn clutch washer - Replace.

4. Jumping in fourth gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Worn gear ring splines - Replace gear ring.
• Worn gear ring pawls - Replace pawls and springs.
• Weak or sticking gear ring pawl springs - Clean the hub, lubricate and/or replace pawl springs.
• Worn secondary sun pinion - Replace secondary sun pinion.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn driver pawls - Replace pawls.
• Worn right hand ball ring ratchet teeth - Replace ball ring.
• Tight or weak clutch spring - Clean the hub and fit new spring.
• Incorrect right hand cone adjustment - Re-adjust the hub
• Worn clutch washer - Replace.
• Worn clutch - Replace.

5. Jumping in fifth gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Worn gear ring splines - Replace gear ring.
• Worn gear ring pawls - Replace pawls and springs.
• Weak or sticking gear ring pawl springs - Clean the hub, lubricate and/or replace pawl springs.
• Worn secondary sun pinion - Replace secondary sun pinion.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn driver pawls - Replace pawls.
• Worn right hand ball ring ratchet teeth - Replace ball ring.
• Tight or weak clutch spring - Clean the hub and fit new spring.
• Incorrect right hand cone adjustment - Re-adjust the hub
• Worn clutch washer - Replace.
• Worn clutch - Replace.
• Worn / ineffective indicator spring - Replace axle assembly.

6. Self changing between 1st and 2nd gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn sun pinion spring - Replace.

7. Self changing between 1st and 3rd gear

• Worn gear ring pawls - Replace pawls and springs.

8. Self changing between 4th and 5th gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Worn or ineffective gear selector key - Replace gear selector key.
• Worn sun pinion spring - Replace.
• Ineffective clutch sleeve spring - Replace.

9. Self changing between high and low gears

• Worn gear ring pawls - Replace pawls and springs.

10. Self changing between 2nd and 3rd gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Ineffective clutch sleeve spring - Replace.

11. Self changing between 3rd and 4th gear

• Kinked or stiff gear cable - Replace or lubricate cable.
• Twisted indicator chain/catching gear selector pulley - Replace indicators/Re-align gear selector pulley.
• Indicators not screwed in fully - Screw in fully.
• Deformed or weak planet cage circlip - Fit new circlip.
• Ineffective clutch sleeve spring - Replace.

12. Hub runs stiffly, drags on pedals when free-wheeling

• Chainstay ends not parallel - Re-align (free-wheeling unparallel chainstay ends can cause axle bending).
• Incorrect cone adjustment - Re-adjust both cones
• Distorted dust caps - Replace dust caps.
• Corrosion due to lack of lubrication - Disassemble hub, clean and re-grease
• Planet pinions are not timed correctly - Check and re-time the pinions (See Diagram 15)
• Brake rubbing (Sprinter Elite hub only) - Re-adjust brakes

13. No gears at all

• Pawls stuck - Clean and re-grease.
• Broken gear selector key - Replace gear selector key.

14. Sluggish gear change

• Rusty or frayed gear cable - Replace cable.

• Worn gear indicator coupling - Replace indicator coupling.
• Bent axle - Fit new axle.
• Damaged axle slots - Fit new axle assembly.
• Distorted axle spring - Replace axle assembly.
• Damaged gear selector key assembly - Replace gear selector key assembly.
• Ineffective cable run - Re-align cable.