DC popped a spring!

Here's another freak CSIesque case I received recently from a customer. This somehow involves someone's foot and a popped 'spring' as well as it sounds weird and rough when cranking. This Shimano MetaniumMg DC is a very solidly built reel using an ultralight magnesium alloy.

The popped spring in question sounds like it's coming from the inside of the crankcase. Shake it hard enough, you hear light rattles.

Mint condition reel, well taken care of but had an unfortunate incident resulted in a need to stripped apart, repair the offending bits as well as give it some new coat of lubrication.

First thing that comes of is the handle cap screw. Some signs of damage from misalignment of screw and crank shaft. Or perhaps from the unfortunate freak incident. I can't tell. Then comes the nasty rough bits from the mechanical brake side spool support bearing.

Slight damage (red arrow with metal shavings) from handle cap screw and crank shaft, no deal breaker. Note the damaged bearing shield (white arrow) and dark pits around the bearing. Hidden surprise when the bearing's removed with rust all over the inside of the bearing as well as the crank case housing. The bearing seemed to have crushed balls inside.

The crushed balls and rusty bearing has created some pits within the bearing housing. Luckily, there were no damages inside of the crank case. Crank case inside looks rather well used and dirty.

Dirty inside. Degreased, contact cleaned and gave it a nice coat of marine grease for water displacement and protection. One way bearing's also given a thin film of one-way bearing oil. No damages, works fine and stops without back play.

Upon cleaning the crank case cover, the bearing housing also given a scrub down to remove rusty bits, some pits have emerged from the rusty concoction soaking for long periods of time. Nothing serious, just some minor cosmetic damages so far.

Notice the light pits in the bearing housing. Offending bearing's replaced with hybrid ceramic bearing.

Popped spring wasn't hard to spot. It's just there, stuck to the top layer of drag discs. The spring looked like it's been crushed a little. Hopefully no between the main gear and pinion gear.

Popped spring spotted (red arrow). Where it's suppose to be. (green arrow). This spring is suppose to pop the centrifugal brake side cover open but somehow got dislodged and went rogue within the crank case. Case still opens fine without the spring, best is just retire the munched up spring.

A thorough clean up by degreasing and dirt removal scrub is definitely needed for such a well used reel. This is probably the first time the insides of this reel seen light.

Visual inspection reveals no major damages. Just old dirt and grease all gunked up.

There are however some permanent dirt stuck on the drag disc as it is an ultralight alloy material that isn't really the most durable material against corrosion and pitting.

As clean as it can possibly be. Looks rather new actually.

Took quite a bit of elbow grease to remove stubborn dirt stains on the drag discs. There seems to have some corrosion and pitting over long periods of time.

Drag discs inner surface shows some minor pitting. Outside looks new & fine. Drag washer material's good as new after cleaning. Pinion gear looks ok after visual inspection. Only a full assembly crank will it reveal if there are any damages sustained on the gears.

Reassembly was rather straight forward without complications. Interspersed with grease coating and assembly to ensure all surfaces is being coated with marine grease for lubrication and protection.

Grease, assemble, grease, assemble, grease, assemble. Repeat after me.

Handle bearings a little rough too. Quick clean up with contact cleaner is all it needs to remove dirt and repack it with marine grease for longer lasting protection and durability.

Contact cleaned and packed with marine grease. Smooth as silk.

Case solved without breaking a sweat. Offending bearing's removed, popped spring removed, gave the internals a new coat of marine grease and it's back ready for some long distance casting.

Ready to fly with one less spring.

The reel now feels like a new creamy smooth reel. Gave it a good few cranks and there seems to have no indication of a damaged gear, just a nasty spool support bearing that's causing most of the roughness. The reel is as good as new now and ready to battle once again.