Sturmey Archer X-RF5 - Gear Selector Key?

[buddha]

I've been having a few issues with my X-RF5 (not the newer Wide ratio hub, but the classic ratio type), which has a 'ball locking' mechanism to lock either sun pinion to the axle.

Somehow I've managed to damage both sun pinions. (Probably down to riding it too hard, according to the LBS). So I replaced these, along with a few other parts. I'm still having problems with 1st gear (jumping and locking-up). All I can put it down to is a damaged 'gear-selector key' (a stepped rod, inside the axle that, moves 6 balls, allowing either sun pinion to lock to the axle). But I can't check that, because it's inside the axle, and 'non-serviceable'. In fact, I don't even know what it's called, as there's no mention of it on the SA service manual.

SA don't appear to sell this 'selector key' itself, just the entire axle assembly - which I assume includes the 'key' and associated spring/pin etc.

Of course, I could just replace this axle assembly. The problem is, that it's £25 and I've already spent £35 on repairs. I can get a complete set of new X-RF5 internals for £50 from oldbiketrader!

Bike shops don't seem to know much about the internals of this hub. And the only mention of this 'selector key' is on a forum where somebody says it is too soft, so prone to wear/damage - and isn't serviceable! And if this part is damaged, I guess it's likely the sun pinions will misalign and get damaged again.

Any ideas on where I can go for advice?
Am I best off ditching this problematic X-RF5 for something else?
Will the X-RF5(W) internals fit inside a X-RF5 shell?

I may just go back to riding S/S again

 

[buddha]

Just updating this thread on the off-chance that someone else has this hub, and gets the same problem some day.

I emailed Peter Read of Phoenix Hub Gear Repairs yesterday, but have yet to hear from him.

Unfortunately, gears 4&5 have gone again, thanks to having to pull away in 5th (after someone overtook, and then decided to stop in front of me a few seconds later - grrr!). I later opened the hub to see the new circlip has jumped out of its groove again, and there is slight wear/damage on the inner splines of both, new, sun pinions.

So, in the meantime, I've botched a way to stop the planet cage pushing the circlip off the axle, by modifying a std axle nut (HMN128) to act as a 'stop'. I had to bore out (to 10.5mm) the thread half-way up the nut, to fit over the unthreaded section of axle, and chamfer the corners of its opposite end to avoid possible contact with the LHS ball race. (I'll post a pic next time I have the hub apart). I left a (<0.25mm) clearance between the end face of the nut and the circlip, and used a drop of thread-lock, just in case.

This means I can use 4th and 5th again, even when riding out of the saddle.