I know this is ancient thread but for someone new who might have same issue. I had same(ish) issue and could not figure out whats going on. My mistaje was that i loosened the drive side bolt and at the same time the driver plate jumped out of position. When i assembled the igh i noticed that the cassette joint units dots didnt line up and driver plate turned freely aprox half a turn.. i just needed to loosen the drive side bolt remove lock and stop washers and reseat driver plate.