This page documents the steps taken to replace the 'G' springs and 'G' spring carrier in a right side Centaur 10 speed shifter. The parts and process are identical for many other Campagnolo Ergo shifters.
The first image shows the names that we'll use to describe the ten or so parts inside the shifter that need to be removed and replaced to gain access to the 'G' springs.
- A. Ergo Centar right side shifter body (central pivot shaft still installed) with rubber hood folded out of the way
- B. 'G' springs
- C. 'G' spring carrier
- D. Spring carrier washer
- E. Index gear
- F. Thumb button return spring
- G. Thumb button return lever
- H. Coil spring bushing washer
- I. Coil spring bushing
- J. Coil spring
- K. Central pivot fixing bolt retention washer
- L. Central pivot fixing bolt
- M. Lever body cap
These steps show how to correctly reassemble your Campagnolo Ergo shifter after it has been disassembled. It is assumed that disassmbly has already taken place. For those that need it the short version of dissassembly is:
- Remove lever body cap (M) and then central pivot fixing bolt (L).
- Carefully wiggle the various springs and parts to remove them. Keep a rag or your hand over the top of the assembly to prevent spring loaded parts from escaping your work area.
- Clean all parts. Inspect 'G' spring carrier (C) closely for damage and cracks.
Once necessary parts are clean and replacements parts are ready we can move on to reassembly.
Place two new 'G' springs (B) into the 'G' spring carrier as shown below. A small dab of grease will hold these springs in position and also allow lubrication after assembly.
Note - For these images we used a damaged 'G' spring carrier. In an effort to better show how the parts are assembled we chose not to apply grease.
The 'G' spring carrier and springs can now be inserted into the Ergo shifter body (A) and the 'G' springs can be positioned away from the central pivot shaft.
Note - In the image below the left side 'G' spring has no grease and is falling down towards the central pivot shaft.
New 'G' spring carriers usually include a new spring carrier washer (D). Install it now. Then spin the central pivot shaft so that the flats are to the left and right as shown in the image below.
The index gear (E) is installed next. If the 'G' springs are in position it should slid in easily. The finger shift lever can be used to help the flats on the central pivot shaft line up with the index gear.
The thumb button return spring (F) rests inside the index gear with it's straight tail positioned into a hole in the plastic Ergo body. That tail can just barely be seen outside the index gear in the eleven oclock position in the image below. It might be easier to insert that tail if the index gear is raised slightly out of position. Some folks like to apply a little grease to this spring although there is not 100% agreement on this point.
Now might be a good time to have a sip of red wine or refill your coffee cup. Gaze out the window and take a few slow deep breaths. Assembly is going to get more challenging from here forward.
Assembling the thumb button return lever (G) onto the thumb button return spring can be pretty frustrating. One of the tricks we like to get the thumb button return spring to cooperate involves a business card. The image below shows how we slide the business card under the hooked end of the spring holding it away from the index gear.
With the hook on the end of the thumb button return spring held in place the thumb button return lever (G) can be threaded on.
Now the thumb button return lever is held flat and rotated towards it's correct position. This will start to preload the thumb button return spring.
Hopefully the hook on the end of the thumb button return spring stays in position while the thumb button return lever is rotated into position. The image below shows that the rotation has been completed but the business card has not yet been removed.
Now we are fighting the thumb button return spring. Push the thumb button return lever so it is centered over the index gear and then pull out the business card. While holding the thumb button return lever in position the coil spring bushing (I) (the coil spring bushing washer (H) should be pre-assembled onto the coil spring bushing) need to be inserted through the hole in the thumb button return lever. To increase the challenge the notch on the end of the coil spring bushing needs to slide over the flats on the end of the central pivot shaft. Expect to execute a couple attempts of this task.
We have experienced some shifters where the central pivot shaft has some play and moves away from the coil spring bushing. When this happens we place a 5mm hex wrench (allen key) into the front end of the central pivot shaft. The brake lever will need to be pulled all the way back and then the 5mm hex wrench will just barely slide over the top of the brake lever and can be wiggled into the central pivot shaft. This hex key can be used to prevent the central pivot shaft from moving away from the coil spring bushing during assembly.
The image below shows the assembly process so far. Although the coil spring bushing is behaving nicely yours probably won't. You'll need to hold it in place with your thumb.
The central pivot fixing bolt can now be temporarily installed to hold the coil spring bushing in place. Use caution when snugging this bolt. It might crush the notch on the end of the coil spring bushing if they are not correctly interlocked. Now the index gear is rotated via the finger shift lever as far as it will go as shown below. During this process you should feel the 'clicks' associated with the various gear positions. If the index gear doesn't move with the same pressure as used for a shift or if there are no 'clicks' it might be time to backup and start over.
Winding the coil spring is the last challenge. We like to start by placing the inner tail into the correct small notch in the coil spring bushing as shown below. Then you need to hold that tail in place while winding the other end over the exposed post of the 'G' spring carrier. This might take a couple tries. Don't expect your spring to hold still for a photo like ours did. We recommend keeping a thumb over that spring.
The last difficult step is to remove the central pivot fixing bolt, slide the central pivot fixing bolt retention washer into place, and then replace the bolt. All while holding the center of the spring down with your thumb. Take note that the central pivot fixing bolt retention washer has a couple tabs that need to be placed into the larger notches showing on the coil spring bushing. Once the bolt is installed a 3mm hex key can be used to carefully tighten it. This is a small fastener and over torquing it could ruin your day.
From here the lever body cap is snapped into place, the rubber hood is manipulated back into place, and the lever is ready for a quick bench test. Tutto fatto.