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· Big is relative
11,901 Posts
Look and see if one of pawls on the freehub is flipped over in the wrong direction. You mentioned the wire on that end of the freehub. That spring wire holds the pawls in place and if out of position, could allow a pawl to flip over and constantly engage on the teeth on the hub side. This can't happen when the freehub is installed, but it could have happened during assembly and would be an intermittent indication. Take the freehub off and make sure all the pawls are identically aligned in the same direction.

I had my chorus hub apart last week to replace the freehub bearings and several times during the fight between me and a snap ring, I accidently flipped the pawls over in the wrong direction.
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