Originally Posted by RubeRad

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?