So one of my Di2 Front mechs has become noisy, shifting a bit sluggish and has a developed a bit of an annoying clicking when auto-trimming.

Bearing in mind its had about 10,000miles over 18 months in the worst kind of weather the UK has experienced in a century! So its well used and I'm not too upset if it needs replacing.

A fix may be possible, but I don't want to destroy it trying, as its currently working and usable.

There's a couple screws that seem to hold the casing for the motor internals on, indicating it could be possible to open this up, clean/lube it, work out what that click is (sounds like the motor is just trying to over trim and hitting a stopper or dropping of the end of a thread and looping round again. Or could be that its all one common problem and a motor mounting point has broke off, which would explain all of the symptoms.

Anyone took one apart before?

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Di2x2

Ok,

So temptation got the better of me.

First, 2 mini screws and the biggie out, allows the cover to be gently seperated from the main body...



Next, slide off the clip-rings from both ends of the "push-rod" (for want of a better name)




Now, the motor body can be rotated around the motor end of said push rod...



Here all my problems are revealed. The click is not a click, its a dry creak. This rod end hinge joint has become practically seized. The motor is having a devilish time trying to force the rod around this joint, its dry creaking when attempting micro-steps, and is causing the motor to whine under extra load.

Lubed up this joint (and the lower one).

Slid the clips back on, rotate the motor body back into place. Case back on, 3 screws in.

Back on the bike and it sounds like new

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Di2x2

Chapeau to you!!!

This should be a sticky!!

great work ..agree needs to be stickied

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tcr's rule !

stefanpearce@rocketmail.com

you sir, have some serious b@11s

i like how it took you all of an hour and one minute to post the first query, sit around waiting for nobody to reply, get antsy, take the der off your bike, take it apart, take pics, post all this new info. you and i must be related!

OP has all the traits I like in a cyclist.

1) Mechanical aptitude.

2) Understanding that certain components need to be maintained and replaced.

3) Ability to document what they did to fix an issue so that others can do the same.

A+

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The Great CarboniO

Very good work!! Thanks for posting with pictures as I'm sure someone along the way will benefit.

Well done sir

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www.thecycleclinic.co.uk

Now forward to Shimano, and suggest they add a lube port to the external case...

Now do the rear mech...

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Cervelo R3, Campagnolo Chorus/Record mix... pastatrails.blogspot.com
And you can call me Macktastik Honey Pete Kicks, thank you.

I had the chrome peel/flack off a section of my Di2 front derailleur cage. Called the Shimano rep & they sent me an advanced replacement.

All Di2 products are designed not be serviced in any way (no lube or solvent cleaning recommended)

Shimano offers a 3 year warranty on all Dura Ace components.

You definitely got your monies worth in miles & conditions used. Plus did a great job of troubleshooting & fixing the problem

As the years add up & the warranty is long expired I would diffidently take mine apart to see what makes it “tick” if it gave me problems.

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"M"
2010 S Works SL3 Tarmac, Di2 with Hutchinson (Corima) Carbon tubeless
2010 S Works Epic, Sram XX with Carbon Roval Control SL

well done!

btw, how far you have to dig to reach the electronics? Or is it sealed in plastic?

That's something not many would venture into. Thanks for sharing.