Sturmey-Archer got back to me, they want to replace the hub & shifter in case there may be some underlying issues. Have to go out an measure the axle, as they said was either 175mm or185mm.
[quote]Thank you for contacting us. Read through your e-mail and even though the hub may be working now it is not right that it is not being adjusted correctly but still working. We would like to replace the internal on the hub for you. We will need to know the axle length in millimeters from end to end on the hub. Will be either 175mm or185mm. Your local shop can replace it for you and should not take them more than ten minutes or so.
The metal wires protruding under the sheath is normal wear as the cable / casing stretches from use. But I will send a replacement shifter your way as well just in case there was some issue with the shifter as well.
Unsure how a hub can be replaced in 10 minutes. The spokes have to come off & be replaced, right?