Stuck cassette

Can you make your cassette tool longer? Put something on the end of the adjustable spanner or breaker bar to create a bigger lever to try and crack it loose?

Alternatively get someone to counterbalance you on the chainwhip and stand on the cassette tool lever. This can be tricky keeping the tool in place and not stripping the lockring splines...

By stuck, do you mean stuck on the freehub even after removing the lockring, or that the lockring won't budge?

just came on to say the same

I have a SRAM cassette stuck on an XD hub.

Do you mean - I haven't got a bit of scaffold pole to go over my lockring tool. Or is that off and the cassette is bitten into the splines

bitten into the splines

Don't have any Shimano freehubs but I think its more a thing with these not XD.

Is it easier to attempt to take it off with freehub attached? Pop it all off the hub and go form there?

Worst case scenario in the latter case is that just the freehub is scrap if the splines are screwed, you can just pull it off along with the cassette if you remove the end caps.

If it's just a stuck lockring, more leverage - a longer bar or wrench on the lockring tool, and maybe a helper to hold everything in place while you heave on it.

If it’s just a stuck lockring, more leverage – a longer bar or wrench on the lockring tool, and maybe a helper to hold everything in place while you heave on it.

Or put the tool in a vise (@ 4:17).

Also, ensure you have removed the end cap to give the best tool fit.

If the lock ring turns but the cassette won’t release, just wind the lock ring all the way out. It’ll elastically deform the cassette, but will be fine. Then place the handle of a mallet of something through the spokes from the other side and smack the back of the cassette off the splines. It should just drop off. If the lock ring won’t turn, penetrating fluid, try and tighten it first and then more leverage to release it.

I'd like to keep the cassette as there's still life in it. It might be that the wheel is knackered, but I'd rather not spend £400 on new wheels and a cassette.

Can't get the locking to move. Using a park tool locking bit with the blue bar so it's fully in, longer bar next.

can't imagine needing to scrap the wheel because the lockring's too tight, so don't panic on that. Just sounds like you need a bigger tool. Worst case you damage the freehub and need a new one of them.

Mine did exactly this a few years ago and went back to Sram and they cut it off.

All replaced.

A mate had one stuck. On the same day he was having some plumbing done on the house. Borrowed his gas torch and used on the lock ring. After it cooled it came off.
Otherwise dremel a couple slots and sacrifice the lock ring.

I use a mallet to hit the lever to give it a bit of a "shock" which has worked for me in the past.

You say its an XD freehub so the suggestions above about removing by heating up the lockring etc... will be no help as XD dosent have a lockring like Shimano

Find the deepest splined lockring tool you have, preferably one like this

https://www.ebay.co.uk/itm/266177032344?hash=item3df9633098:g:u58AAOSw3PVkFJoi

Next try one or both of the following

Spray some GT85/WD40 into the back of the cassette/freehub and leave overnight

Clamp the lockring tool in a vice, drop the wheel & cassette onto the lockring then using the wheel for leverage turn the wheel to unscrew the freehub, it may take 2 people to do this, one to hold the chain whip whilst you turn the wheel

Other option is to fit the lockring tool and then use a socket and ratchet bar along with the longest bar you can find that will slide over the end of the ratchet bar, get someone to hold the wheel and chain whip steady whilst you hang off the bar and it should free off

If no luck or you dont fancy trying then take it to your LBS, it wont be the first time they have done one

Worst case scenario they cant remove it so its a new freehub body and cassette

When you refit the XD freehub make sure the cassette and freehub are clean and apply some grease to aid removal next time

Last time this happened to me after neglecting my usual service intervals I sprayed a good amount of penetrant spray / liquid wrench into the back of the cassette where it would coat the splines and thread and left it overnight. Came off super easy the next morning.

XD driver - typical SRAM poor engineering with a number of flaws. When you put it all back together again be sure to apply a liberal amount of grease or anti-seize to everything.

The absolutely easiest way of doing this if your freehub pops off when pulled is to put a couple of bolts in the vice the right distance to fit in the back of the cassette and use the cassette tool without a chain whip.
When I had xd this became my default way as it didn’t play well with the Hope 2 evo hub.
There’s a vid of guy in his shed somewhere if you need a visual guide.

I've had exactly the same trouble. I took it to my local wheelbuilder guy and we bolted the spline tool in the bench vice and put the wheel on top, cassette side down. Then we had both of us with two chainwhips (can help to zip tie these to the sprockets to make sure they don't ping off) and ALL of our combined weights and it budged.

Not sure why it was so tough - SRAM/Zipp hub and SRAM cassette, lots of grease on installation too...

As above, vice did it for me, very loud crack when it released!