Brian,

You're right, it should be an exciting learning process to work on this old Schwinn. They are great bikes, built like a rock and heavy as a rock!

As TimJ has mentioned, and from most of what I've read, there's really no need to rebuild the hub if it works properly. I simply did it because I was interested in seeing the insides of the hub and inspecting the parts.

I used the karrot.org website as a pictorial guide, and it's probably all you need. I rebuilt an AW hub, one of the most common and least complex from what I've heard.

Another great website is http://www.users.globalnet.co.uk/~ha...samaintind.htm which is a good technical supplement to the karrot.org website, but does not include a step-by-step pictorial guide.

It has a technical guide to the TCW there. It looks like the TCW also has a coaster brake, which I've heard is a little more complex than those without. But that doesn't mean it's impossible to rebuild.

I'll let you know that I have very little mechanical aptitude, but I found the rebuilt relatively simple, and I was able to clean the tar that had accumulated on the parts.

Be sure to check Harris Cyclery if you need parts, or try the Schwinn Forums. I didn't get help there, but from what I understand there are some very helpful and generous enthusiasts there. Also, you might want to post your rebuild as a thread here. As you can see from this thread, lots of interested and helpful enthusiasts on the BF Forums too! I'll also be willing to answer any questions you have as you go along, to the best of my ability and knowledge (which is very limited mind you!)

Finally, as per the greasing of the bearings, this is the information I received on the Mechanics Forum of BF. I ended up using white lithium sparingly, and having opened it since, can attest that it becomes diluted and spreads everywhere. Not sure yet whether it will have a long term negative effect. As of now, it is very viscous. It may become a problem later as the grease ages.

Good luck, and keep us posted!