Trek 2022 E-CALIBER Operating manual

2022 E-CALIBER

SERVICE MANUAL SUPPLEMENT

2022 E-Caliber Service Manual

Contents

Safety 1

Headset with Knock Block 2

Frame and drive system guards 3

Rear triangle and chainstay bridge 4

Main pivot 6

Derailleur hanger 7

Cabling overview 8

IsoStrut remote lockout cable 9

IsoStrut 10

Air volume spacer 11

Carriage wiper seals and bushings 14

Fazua system 19

Specications 20

Suspension 21

Safety

WARNING

Alwaystightenhardwaretothespeciedtorque.

Over-tightening hardware could deform or break the

hardwareorcomponents.Under-tighteninghardware

couldcausehardwareorcomponentstobecomeloose.

Either situation could damage the bicycle and result in

injurytotherider.

WARNING

All reused-fasteners with pre-applied threadlocker must

be cleaned with isopropyl alcohol and have new thread-

lockerappliedbeforere-assembly.Ifthreadlockerisnot

applied, the fasteners may loosen which could damage

thebicycleandresultininjurytotherider.

2022 E-Caliber Service Manual

Headset with Knock Block

Item Description

Quantity in

Assembly Part Number Torque (Nm)

1 Upperbearingcover 1

5252159

—

2 Knock Block chip bolt 1 2

3 Knock Block chip, 62 degrees 1 —

4 Compression ring 1 —

5 Upperbearing 1 —

6 Lower bearing 1 5252158 —

7 Crown race 1 —

Tools

• 2.5mmhextool

• Torquewrenchwith2.5mmhexbit

• Headset tools

• Grease

1. Inspectthecomponentsfordamageorexcessive

wear.

• Knock Block chip (3)

• Undersidechanneloftheupperbearingcover(1)

• Interlocking keys of the upper bearing cover (1)

and the stem

2. Replaceanydamagedorworncomponents.

3. Apply grease to:

• Upperandlowerheadtubebearingbores.

• Inside of the bearing seats of the compression

ring(4)andthecrownrace(7).

4. Install the crown race (7), then the lower bearing (6)

ontothesteerertube.

5. Insert the steerer tube into the bottom of the head

tube.

6. Install the upper bearing (5), then the compression

ring(4)ontothesteerertube.

7. Insert the Knock Block chip (3) and bolt (2) into the

frame,butdonottightenit.

8. Installtheupperbearingcover(1).

9. Installspacersasneeded.

10. TorquetheKnockBlockchipbolt(2)to2Nm.

2022 E-Caliber Service Manual

Frame and drive system guards

Item Description

Quantity in

Assembly Part Number Torque (Nm)

1 Chainstay guard 1 W582883 —

2 Down tube guard 1 W582884 —

3 Drive unit guard fasteners 4 5269023 3

4 Drive unit guard 1 W1040440 —

Chainstay and down tube guards

Useisopropylalcoholtocleantheframesurfacewherethe

guardsattach.Waitforthealcoholtodrybeforeapplying

theguards.

Notice: Do not clean the entire frame with isopropyl

alcohol.Isopropylalcoholcoulddamagethepaint.

2022 E-Caliber Service Manual

Rear triangle and chainstay bridge

Item Description

Quantity in

Assembly Part Number Torque (Nm)

1 RearIsoStrutaxle 1 591626 10

2 End cap bolt 1 —

3 Front IsoStrut bolt and washer 2 W584485 5

4 Chainstay bridge bolt 4 5265697 8

5 Chainstay bridge, charcoal color 1 5266755 —

Tools

• Bike repair stand

• Torquewrenchwith6mmhexbit,T25andT30

Torxbits

• Grease

Important: You must have the main pivot bearing and

sleeve (See the Main pivot section on page 6) and the

IsoStrut (See the IsoStrut section on page 10) installed

on the rear triangle before attaching the rear triangle to

theframe.

1. Puttheseatpostinabikerepairstand.

2. Fitthereartriangleintothemainframe.

3. InstallthetwofrontIsoStrutboltsandwashers(3).

Important: Donottorquetheboltsatthistime.

4. Apply greasetotheIsoStrutrearaxle(1).

5. InstalltheIsoStrutrearaxle(1)andendcapbolt(2).

Important: Donottorquetheboltsatthistime.

6. Applygreasetotheatsurfacesofthechainstay

bridge(5).

2022 E-Caliber Service Manual

Rear triangle and chainstay bridge (continued)

7. Insert the chainstay bridge (5) inside the rear

triangle.

8. Install the four bridge bolts (4) to attach the bridge to

thereartriangle.

9. If applicable, install the main pivot hardware before

torquingthebridgebolts(4).SeetheMain pivot

section on page 6.

10. Torque:

• Chainstaybridgebolts(4)to8Nm.

• IsoStrutrearaxle(1)to10Nm.

• FrontIsoStrutbolts(3)to5Nm.

2022 E-Caliber Service Manual

Main pivot

234

Item Description Quantity in

Assembly

Part Number Torque (Nm)

1 Main pivot nut 1 W584134 —

2 Washer 2 W440921 —

3 Main pivot bearing 2 W302025 —

4 Main pivot sleeve 1 W600642 —

5 Main pivot bolt 1 W600628 30

Tools

• Bearing press

• 8mmhextool

• Torquewrenchwith8mmhexbit

• Grease

1. Pressinthedrivesidebearing(3).

2. Insertthesleeve(4)fromthenon-driveside.

3. Press-inthenon-drivesidebearing(3).

4. Position the chainstay over the seat tube, making

surethemainpivotholesarealigned.

Tip: Slidethelongarmofthehextoolfromthenon-

drivesideandthroughthealignedpivotholes.For

eachstep,slidethecomponentontothehextoolto

alignthecomponentsoneachsideofthemainpivot.

5. Apply grease to the shoulder of the main pivot

bolt(5).

6. Insert the driveside washer (2) between the bearing

thechainstay.

7. Partially insert the main pivot bolt (5) from the drive

side.

8. Insert the non-driveside washer (2) bewtween the

bearingthechainstay.

9. Fullyinsertthemainpivotbolt(5).

10. Installthenut(1).

11. Torquethemainpivotbolt(5)to30Nm.

2022 E-Caliber Service Manual

Derailleur hanger

Item Description Quantity in

Assembly

Part Number Torque (Nm)

1 Thruaxle,M12X1.0X15MM 1 W600321 10

2 Derailleur hanger 1

W600660

—

Hanger bolt, left-handed thread 1 25

Washer, 25mm 1 —

ThisbicycleframeisdesignedtouseaUniversalDerailleur

Hanger(UDH).

NOTICE: ThethruaxlemustbecompatiblewithaUDH

andmustbeM12x1.0witha12.7mmthread.

NOTICE: Thewasherisframe-specic.Installonlythe

washercompatiblewithyourframe.

WARNING

Donotapplygreasetothederailleurhangerorbolt.

Applygreasetoonlythethruaxle.

1. Insert the hanger on the inside of the driveside

chainstay.

2. Installthewasheronthederailleurhangerbolt.

3. Inserttheboltintotheframe.

4. Makesurethehangerispositionedasshownbelow.

5. Torquethehangerboltto25Nm.

NOTICE: Donotover-tighten.Over-tighteningthebolt

couldcausethehangertobreak.

ForadditionalinformationabouttheUDH,refertothe

SRAM user manual at sram.com.

2022 E-Caliber Service Manual

Cabling overview



Item Description Quantity in

Assembly

Part Number Torque (Nm)

1 Bolt 1 W562831 3

2 Speed sensor 1 W581396 —

3 Rear brake cable 1 — —

4 Speed sensor cable 1 — —

5 Dropper post cable 1 — —

6 IsoStrut lockout cable 1 — —

7 Head tube cable guide 2 W519232 —

8 Head tube cable guide fastener 2 W532763 1

9 Controller cable 1 — —

10 Down tube cable guide 3 W591416 —

11 Rear derailleur cable 1 — —

12 Grommet, for use with wireless derailleur only 1 5259425 —

Zip tie location 4 — —

Routeandziptiethecablesasshownintheillustrationabove.

Dropper cable

• For detailed dropper remote instructions, please refer

to the Drop Lock Remote manual at trekbikes.com/

manuals.

IsoStrut cable

• See the IsoStrut remote lockout cable section on

page 9.

2022 E-Caliber Service Manual

IsoStrut remote lockout cable

Tools

• Cable cutter

• Torquewrenchwith2mmhexbit

1. Installthecableintheremotelockout.

2. Route the cable through the hole in the bottom of the

top tube just forward of the IsoStrut and out the drive

sideoftheheadtubehole.

3. Attheheadtube,routethewirethroughthecable.

4. AttheIsoStrut,slidetheferruleonthewire.

5. Guidethewirethroughtheslotinthecablestop.

6. Route the wire around the lockout spool and install

thesetscrew.Torqueto1Nm.

Drive side Non-driveside

7. Testthatthemechanismworkssatisfactorily.

8. Cut the wire to the appropriate length (20-30mm)

andcrimpanendcaponit.

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