Kalkhoff / Shimano 8 speed internal hub problem.

[fergusgorman]

Hello please could someone advice me on my Shimano 8 Speed Nexus Internal Gear Hub for my Kalkhoff bike. The other night I was riding hope when terrible cracking started no matter what gear i was in. was like it was coming out of gear on load. Managed to get home. I stripped the hub and
cleaned out the assembly and re-greased. However on assembly I am sure there is a problem. The attached picture will show where the driver plate is supposed to position. However i presume there must be two prongs that stick out to allow the driver plate to locate. I think (presume) these have snapped off. Does anyone have any idea if I am correct. Its the only way I would see that the driver plate could rotate the internals of the unit. Please see attached photo. Many Thanks Fergus

sorry about the blurry image. You can just see the prongs dont appear to be there for the driver plate to lock onto.

 

[103Alex1]

I've never taken one apart but Sheldon Brown linked a service manual for them which might help answer your question if no-one else can advise specifically :

Shimano Nexus 8-speed Hub - Service Manual

 

[Geebee]

Could the cable have been binding anywhere, thats the sound mine made when the hub rotated the cable guide and stopped the cable shifting smoothly so you end up with the gears not meshing properly.

 

[johnc461165]

Did you find any metal fragments inside when you cleaned it, if not it's unlikely that something has broken internally.