The AW hub:

To dismantle

1. Remove the hub internal as described in the general instructions.
2. Remove the low gear pawls, pins and springs. The pawl pins are easily pushed out of the planet cage to release the pawls and springs.
3. Place the left-hand end of the axle in a vice and remove the right hand locknut, washers if any, cone lock washer and cone, making a note of their arrangement so that they can be replaced in their original positions.
4. Lift off in the following order, the clutch spring and cap, the driver, the right-hand ball ring and the gear ring.
5. Remove the gear ring pawls, pins and springs. The pawl pins are easily pushed out of the gear ring to release the pawls and springs.
6. Remove the thrust ring and washer, and unscrew the indicator rod.
7. Push out the axle key and remove the sliding clutch and sleeve.
8. Lift off the planet cage complete.
9. Take out the pinion pins and remove the pinions from the planet cage.
10. If necessary, because of a worn bearing surface or ratchets, the left-hand ball cup may be removed from hub shell. It has a left hand thread and is removed by gripping the outside flat surfaces in a vice and turning the wheel in a clockwise direction.
11. The channel-section dust cap in the left-hand ball cup similar to that in the driver is a press-in fit and may be prised out with-a wide screwdriver to avoid damage. If a new ball retainer and balls have to be fitted it is recommended that a new dust cap is fitted at the same time.

Reassembly

1. If the left-hand ball cup has been removed from the hub shell, replace it by screwing anti-clockwise (it has a left-hand thread).
2. Prepare the following preliminary sub-assemblies:
   • Fit the ball cage into the left-hand ball cup, with the ring of the ball-retainer facing outwards and the recess in the dust cap also facing outwards. If a new ball-retainer is being fitted, the dust cap also should be new
   • Fit the ball cage into the driver, with the ring of the ball retainer facing outwards and the recess in the dust cap also facing outwards. If a new ball-retainer is being fitted, the dust cap also should be new. If the sprocket has been removed, see no. 17 below
   • Fit the balls (only 24) and the inner dust cap to the right-hand ball ring, making sure that the balls can revolve freely with the dust cap in place.
   • Fit the pawls, pins, and springs into the gear ring as described in the general instructions to 'The Re-assembling of Sturmey Archer hubs.(The planet-cage pawls, pins and springs are not fitted at this stage.)
   • Smear grease in the channels of the dust caps of the left-hand ball cup and the driver and in the recess of the right-hand ball ring. Do not use grease anywhere else
3. Hold the left-hand end of the axle in a vice, so that the slot for the axle key is above the sun pinion, and fit the planet cage.
4. Add the planet pinions and pins. (The small ends of the pins protrude.)
5. Fit the sleeve (flange first), the sliding clutch with recess on the flange of the sleeve, and the axle key (with the flat of the key facing upwards), and screw in the indicator rod to hold them in that position.
6. Fit the thrust ring and washer, making sure that the flatted ends of the key engage properly in the slots of the thrust ring.
7. Fit the previously prepared gear-ring sub-assembly.
8. Fit the previously prepared right-hand ball-ring sub-assembly.
9. Fit the previously prepared driver sub-assembly.
10. Drop the clutch spring over the axle
11. Fit the cap and screw up the right-hand cone fixer tight. Then slacken it back half a turn and lock it in that posation with the special washer and locknut. On no account must the cone be unscrewed more than half a turn, as that would throw the gear mechanism out of adjustment.
12. Invert the assembly in the vice and fit the planet-cage pawls as described in the general instructions to 'The Re-assembling of Sturmey-Archer Hubs.
13. Remove the assembled mechanism from the vice and, while holding it with the planet cage uppermost, pour about two teaspoonfuls of a good quality thin oil into the cage.
14. Hold the cycle wheel in the left hand, with the open (right-hand) end of the hub shell facing downwards, and insert the assembled mechanism from below, screwing-up the right-hand ball ring finger tight only.
15. Make sure that the position marks made on the ball ring and the hub flange before dismantling will register properly, and then screw up tightly.
16. Fit the left-hand cone, washers (if any), and locknut in the arrangement noted when dismantling, and adjust the hub bearings as described in 'The Fitting and Adjustment of Sturmey-Archer Hubs."
17. If the sprocket has been removed from the driver, fit the outer dust cap over the driver before replacing the sprocket, and see that the dust cap is properly centred on the flange of the driver. Replace the sprocket and spacing washers in the arrangement noted when dismantling, and add the circlip.
18. Replace the wheel in the cycle frame and adjust the gear as described in 'The Fitting and Adjustment of Sturmey-Archer Hubs.'

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