Update for the curious.
Wednesday night I couldn't hold back my curiosity and pulled the axle to see what the damage was this time. Surprisingly the main balls and races looked to be in good condition. The grease in the races was a little discoloured, possibly emulsion. Spinning the axle prior to removal there was no great resistance or rough spots, so this pointed to the freehub causing the noise. The first time I took this hub apart, there had been moisture in the non drive side bearing and the freehub. The steel push-in washer had been installed skew and so the wiper seal that sits on the cone nut was not in full contact with this washer to provide ingress protection. I ordered the repair kit from Scott and had it fitted by a local shop that had all the requisite tools.
Jump to now, I open up and find that the wiper seal was never installed by the shop that did the repair. Luckily I asked to keep the old parts, so I've scavenged the old one to put back. There was dirt and grit near the ball bearings, looks like excess grease emerged on the non drive side (probably all over my disc unknowingly). Most of the moisture seems to have ended up in the freehub causing significant damage.
I have stripped and cleaned the balls, cups and cones ready for reassembly. I don't have the tool to disassemble the freehub, but I washed out with degreaser, alcohol and acetone to try and remove all the crud and rust. It is pretty much trash. I think the pawls have corroded. They still tick over, but the feeling is very rough. After rinsing and repeating I repacked the main race on the freehub, the balls are pitted and rough, but they only have to make it until I get a replacement.
I'll put it all back together tonight for a short ride tomorrow, then get to grips with my options.
The rusted, gritty freehub with inner seal removed to expose the ball bearings.
Locking nut, shield and cone nut that came off the drive side end, no wiper seal installed.
The wiper seal that should have been there from the kit (or reused from the old parts).
Evidence on the non drive side of grease escaping.
The pitted and corroded balls.
Rusty pawl just visible through the races.
Regards,
Ledz
