Been a fun couple of days, I've been meaning to try pulling the gear hubs to pieces on my old bikes for cleaning and some other maintenance (Worn pawls and such) - I decided to strip a spare AW hub (Dated 1980 Week 3) to pieces first, have a look at all the bits and pieces in the document if you want;
http://www.users.glo...and/sa/saaw.pdf
Anyhow, this worked fine when I re-built it, I decided, however, to take it to pieces again and use it if any parts were needed on the old bikes (as several parts, such as pawls and gears are the same as their 1920's counterparts) - the old bicycles I have use K hubs, probably 1936-1937, I have successfully dismantled the one on my Raleigh tourist, about 50% of the weight must have been hardened grease and dirt, grease and dirt do not mix well on moving parts, they act like sand paper and chip the teeth on gears not to mention other problems they cause in a precision device like a gear hub, a reccuring theme with this bike is cones/bearing being ruined, the left hand bearing cage was completely split and the bearings were loose and pieces of cage were in the left side of the hub (why first gear was so rough and slipped) but no problem, the bearings used in the AW are the same, so those were cleaned and donated, the Pawls were worn and so they were replaced, the clutch axle was a bugger to remove and put back in as the clutch sleve covers the spring, but the spring is in the way of the hole, it's pure luck that gets that thing back in, to make it worse, the clutch axle has a hole through the middle that you push the indicator rod through, lining that up blind is not fun. I don't have anywhere to work on this, so it was all done on a sheet of hardboard in my living room, so that smells like a gas station now with all the degreaser, grease and oil I used.
All in all, the hub has certainly seen better days, but to say how old it is and where it has spent most of it's life, it ain't half bad, successfully rebuilt and working, it is now much more quiet, but sounds kind of hollow without all that dirt, changing gear is almost instant, there is no slip, no matter how much force I apply to the pedals, of course I've flooded the thing with oil and will keep doing so for the next few days and once I get the spokes sorted, some were snapped - how could I not notice, given that I already replaced loads of them - I will have to ride it properly and make sure I get the oil worked into things properly, nontheless, it's a job well done if I do say so myself, now I have to do the same to the other one, and I don't doubt I will end up stinking even worse after that. Anyways, if you want to see what I have had fun with, check the document I reffered to for help dismantling this thing;
http://www.users.glo...adland/sa/k.pdf
Look how many bloody parts they have! Still, they don't make them like they used to, my Shimano gears are always screwed after six months, these gears have been runing for almost a century, that is an acheivement if you ask me, the guys from Sturmey Archer should be proud.