Firstly, I'm not sure if this post is in the right place.
I've stripped down and fully cleaned a Sturmey Archer AW 3 speed hub (1990). Its in a good condition, nothing looks 'worn'. I've replaced the pawl springs and the bearings. I've greased the bearings and re-oiled the lot. The shifter cable (inner and outer) is new and the twist grip shifter works well.
When fitted, I can only get two gears to engage, even with the adjuster indicator chain separated from the shifter cable, as to rule out any adjustment problems.
Following extensive indicator chain/spindle the two gears work well, shifting reliably with out slipping at any point.
There is no third gear to be found, at any position of the indicator spindle.
Can anyone suggest a cause or something that needs further adjustment?
Was there 3 gears engaging before you stripped this down or is this a hub you haven't used before. I know you have said that even without the linkage attached, you can't seem to get 3 gears, but what method of initial setup are you using?
With the trigger/grip set to gear 2, you should adjust the toggle chain linkage so that the shoulder of the main shaft of the toggle chain is in line with the edge of the hub axle when viewed through the hold in the axle nut.
What guide did you use when stripping the hub - does the guide you have used show that you have all internal/external parts in the correct order?
_________________SBDU Specials : SB4409
1981 Dynaflite 753 Aero TubingSBDU Time Trial Specials : SB2692
1978 753, SB5464
1982 531 Special Lightweight, SB5794
1983 531cSBDU Road : SB1688
1977 Team Pro 531, SB3800
1980 Team Pro 753, SB4059
1980 Team Pro 753 Super Record, SB4944
1982 531SL, SB5377
1982 753, SB6398
1984 753R 50th Anniversary Super Record, SB6560
1984 531c Panasonic Raleigh Services des Courses, SB7121
1985 753R, SB7219
1985 531 Pro Super, SB8868
1988 753R Services des Courses, SB8945
1988 753R Services des CoursesSBDU Randonneur : SB7657
1985 753R, SB7660
1985 531cSBDU Track : JR178T
1978 Jan Raas Track Frame 531, SB632
1976 753 Pursuit Track Framehttp://raleigh-sb4059.com/