The gearbox has been skipping gears and generally being a bit unreliable.
After a bit of investigation I found that the thread on the axle has worn down so that when the nut on the end of the axle is tightened it can easily come loose again. With the nut loose the washers that lock the rotation of the axle can then disengage with the frame and this gives nothing for the gearbox to react against so then the gears then don't work.
I have found a replacement axle from SJS cycles so here's a simplified strip down of the gearbox to get the original axle out and switch in the new one.
It's not that clear but you can just see on the end of the axle the thread has worn down.
All the insides...
The new axle compared with the old one.
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