New Departure Model D Rebuild

[udallcustombikes]

Not a problem, Randy. These are one of my favorite hubs to rebuild (and ride).

[Bigwaves]

Hey folks! Great site. I have been lurking and learning for a while. I will post pix of my '61 Schwinn American I have been cobbling together in the proper area when appropriate.

I followed the instructions and did a rebuild of my ND modD hub. All went well, I think.

I noticed 3 teeth were missing on the "brake washer shoes" (single tooth on 3 different discs) after cleaning and light wet/dry sanding - upon reassemble, I made sure to spread the missing teeth out and not in same alignment. Just seemed logical, right or wrong!
Here is my area of question...
I can lock up the brake and create a skid when desired. However, sometimes, it can rotate almost 3/4 reverse turn prior to break engaging. Additionally, when starting out, the crank can turn almost a full turn prior to drive engaging.

Is this a simple cone adjustment, or do I need to reassemble differently. I have pics, but do not know how to post!
Thanks in advance
Steve

[deorman]

Do you have enough discs? (8 outer tab, 7 inside slot) Also make sure the transfer spring is snug and facing the right way on the brake clutch, it should only be able to spin in one direction. Pics-if you have web posting as part of your internet service, upload to your page, hit the Img button on the RRB post form, and enter the pic address. Otherwise, look here viewtopic.php?f=6&t=172

[Rat Rod]

Good stuff here!

[udallcustombikes]

Do you have enough discs? (8 outer tab, 7 inside slot)

Depending on the specific hub the numbers may vary. Some years they used different thickness' of discs, some used all steel, some used bronze for the tabbed discs. Total width of the disc stack should be about 19mm regardless of the quantity.

[c.p.odom]

Try this for an assembly video:

http://s1197.photobucket.com/albums/aa4 ... DHUB-2.mp4

[Bigwaves]

I don't have pictures of all prior to assem, here are the discs. I did assem just like the vid posted. Everything went together fine.
What could cause it to not engage immediately upon forward peddle? I am new to this and this is really my first rebuild since I was a kid 45 years ago!!

[Blueboy5000]

The model D does indeed assemble in this configuration. However, according to my ancient New Departure booklet, the hub should not be lubricated with grease! New Departure recommends using "high quality oil".

So after you soak your inner hub parts in solvent (brake parts cleaner is even better, and don't hesitate to scrub parts with a brush) examine your brass clutch washers. If they're shiny, scuff off the shine with Emory paper, then make sure your internals and hub are grease, oil and dirt free, and then reassemble.

Oil your hub by adding "high quality oil" (I recommend Marvel Mystery Oil) through the oil fitting. Add oil in small amounts while operating your hub and spinning the wheel. This will help you evenly distribute the oil. It doesn't hold much oil, only about 1.5 ounces. Fill with oil until oil weeps out of the dust covers.

Now that your properly assembled and lubed, have fun pulling the best coaster skids the world has ever seen

[Blueboy5000]

Bigwaves, that bearing goes outside that mechanism, the bearings go in the bearing races on the oustides of the hubs. Check out the exploded and cut-away diagram/pics on page 1.

[udallcustombikes]

Bigwaves, that bearing goes outside that mechanism, the bearings go in the bearing races on the oustides of the hubs. Check out the exploded and cut-away diagram/pics on page 1.

The bearing is in the correct place. It has to be on there before the brake pack. Check the cut-away.

[Blueboy5000]

Whoops. My bad.

[Bigwaves]

Hey guys! Thanks follow up. I have been riding the bike for a couple of months now, however when you first start out, the crank does rotate maybe 1/2 turn before it engages. I have not had time to take it apart again. More of a nuisance than anything else. Although I do know something is not quite right. I used the cutaway photo for my reference, even printed it out. I hope you don't mind me posting these.
Finding this old photo of me from 1964 is what inspired me to re build this 1961 frame I came across.


Rebuild 1961 Schwinn American

[acharles331]

Just what I need. I just got a bicycle with this hub on it and it looks like it has years of gunk on it. I'll be taking it apart on hopefully get it running smooth as butter. Great post! Thanks.

[acharles331]

Ok so I broke down my rear hub today and cleaned it out. First time doing this and everything was pretty straight forwards. The only question I have is do I put grease on the little discs found inside the hub? I put grease on them and now I feel like the hub doesn't move as free, feels a bit stiff. Another question, the rod that runs through the hub sticks out by about an inch on once side of the hub, is this normal?

[udallcustombikes]

Ok so I broke down my rear hub today and cleaned it out. First time doing this and everything was pretty straight forwards. The only question I have is do I put grease on the little discs found inside the hub? I put grease on them and now I feel like the hub doesn't move as free, feels a bit stiff. Another question, the rod that runs through the hub sticks out by about an inch on once side of the hub, is this normal?

The brake disc pack should be lubricated with oil, not grease. I use 3in1 oil or standard 30wt automotive oil.

What rod are you asking about? The axle? Some pictures of what you are asking about will help get an accurate answer.or you can reference the parts drawing on the first page of the thread.