Originally Posted by
Ghrumpy
Without knowing or seeing anything of your specific hub, it sounds like this happened: Cogsets with individual steel cogs will wear notches into the splines of aluminum freehub bodies. (That's why the biggest cogs, which create the most torque, are on aluminum carriers.) Those notches push up burrs on either side of the small notch, which impedes removal of the old cassette .Those burrs need to be trimmed down with a file before you install the new cassette.
Thanks for an actual response!
There were some visible burrs on the cassette, but they didn't seem significant. I guess a miniscule amount of burring, if on enough of the splines, adds up to less tolerance all around.
Taking a file to the splines sounds like a good idea.
Are there hubs where it's normal for the freehub body to just pull off by hand when the cassette lockring is removed?