pstock

A Campagnolo Zona rear wheel was running a bit rough.
So, I decided to take it apart and repack it.

Seemed straight forward enough. until the freewheel bit came out and the spring loaded paws popped out....
Still, it seemed straight forward enough. I dealt with the bearings, cleaned it up, regreased. but on reassembly I am having a heck of a time getting it to run clean.

First the splined bit had to be tweaked back into place.
But slightly too tight and the whole rachet binds.
Too loose.. well, that's not good.

can anyone guide me in reassembly steps or tricks?

is the splined bit (freewheel? I don't know the names for the bits) just held in position by the cones and lock nuts?
does the freewheel (the splined tubey bit) thread into the hub body?

for instance, there is a small allen key bolt on the drive side lock nut, presumably to reposition the axle left or right. I don't think I touched it but ...

(no comments on the mess. Zinn said to flow lube in until the paws quieted down. Maybe I overdid it.)

reptilezs

use a rubber band around the pawls so thy dont fall out. the free hub body needs to be seated further in the hub shell. you can also get the campy spring tool or make one with a spoke

Drew Eckhardt 

For your hub vintage Campagnolo provided a metal clip which holds the pawls in place when reassembling the hub. 9 speed+ freehubs came with a plastic piece which is less necessary because they use a different spring arrangement which traps the pawls.

As reptilezs noted your freehub isn't all the way on. Wiggle the freehub (rotation in the freewheeling direction will help depress the pawls as they start to seat), poke at the pawls so they clear the ratchet ring inside the hub, and you should be able to get it on without using one of the Campagnolo tools.

The non-drive side seats against a shoulder on the axle. The drive side is held in place by a lock washer, one or two flat washers (the parts diagrams show two; the two 1996 hubs I own came with one but needed a second added when I installed 9 speed freehub bodies for the chain to clear my drive side dropout in the small cog), and the nut with the set screw. Once you get the freehub seated tighten the nut down until it stops turning (don't kill it), tighten the set screw, and you should be in fine shape.

It's the seating problem as noted.