How to Rebuild a Freewheel: A Comprehensive Guide

Rebuilding a freewheel can be a daunting task, but it’s often a necessary step to keep your bicycle running smoothly. While you don’t need to remove the sprockets to rebuild the internal mechanism, doing so can make the process easier and allow you to clean and regrind them if needed.

Disassembling the Freewheel

To begin, you’ll need to remove the freewheel from the wheel. This can be done using a freewheel remover tool, which is designed to unscrew the freewheel from the wheel in a counterclockwise direction.4 Be prepared for this to be a tight fit, as the freewheel can sometimes be difficult to remove.
Once the freewheel is off the wheel, you can start disassembling it. The external retainer ring that holds the sprockets in place typically has a standard (lefty-loosey) thread, so you can unscrew it counterclockwise. Be careful not to lose any of the shims that may be underneath the retainer ring, as they are crucial for proper reassembly.

Cleaning and Lubricating the Freewheel

With the freewheel disassembled, you can now thoroughly clean all the parts using a solvent, followed by a strong solution of dishwashing detergent and a water rinse. This will help remove any built-up grime or debris that may be causing the gritty noise you’re experiencing.
After cleaning, you can apply a thick grease to help stick the bearing balls in place during reassembly. You may also want to consider replacing the bearings if they show signs of wear or damage.4

Reassembling the Freewheel

When reassembling the freewheel, be sure to keep track of the order of the sprockets and spacers as you remove them. The inner sprockets on older European freewheels are often left-threaded and come off the back, so be mindful of this.
Once all the parts are clean and ready, you can begin reassembling the freewheel. Start by inserting the bearing balls into the race, leaving room for a few more. Then, carefully reinsert the pawls and pawl springs, ensuring they are properly aligned.4
Finally, screw the retainer ring back on, being careful not to lose any of the shims. You may need to use a pin spanner or a punch and hammer to get the ring tight.
With the freewheel reassembled, you can now reinstall it on the wheel and enjoy a smoother, quieter ride.