I'm opening up a New Departure Model D tomorrow, has anyone else worked on these?

Here's the issue: the hub does not brake reliably. Basically what happens is that the brake ONLY works when backwards force is applied directly after forward pedaling. If you were to pedal forward, then coast, then attempt to apply the brake, it doesn't work. You would just pedal backwards to no success.

This hub has an oil port, does this mean that the hub should NOT be greased? I've read that most coaster hubs are to be packed liberally with grease, but this one would then be oil lubed and should be left to oil (well besides the cones)?

Look here: https://www.johnsvintagebikes.com/cha...rturePage1.jpg
Lightly grease the discs, driver, and clutch on assembly, pack the bearings with light grease, oil after assembly and every month or so thereafter. 20 or 30 weight motor oil, the excess ends up all over the wheel and chain stays, so 5 drops max.

On model Ds there is a spring that wears out and should be replaced everytime the hub is opened. It helps apply the brakes. Good luck finding one. Roger

Any advice on re-assembly?

I'm having a difficult time getting it all back together and lining up the discs so they slide through the tabs in the hub shell.