Originally Posted by FBinNY

Before we go at this to cross purposes, we need an accurate description of the hub and problem.

Is the dust cover (shield) pressed onto the cone like Brad's or into the shell? Everything turns on that (no pun).

If it's part of the axle or cone, then simply tapping it in deeper is the answer. If it's pressed into the shell, you have to check the why the freewheel body is pressing on it, and why it jams.

As I said earlier, you're the only one here who has it in your hands, so the quality of the answer anybody gives depends on the accuracy and completeness of the description.

As for removing a ball, that won't change anything, unless you put in one too many when you rebuilt.