Originally Posted by woodinville guy
I should clarrify the problem I am having, the cassette has somehow chewed into the freehub splines. That must be where the creaking is coming from but I can't get the cassette off to replace the freewheel cap with the splines.
You need a chain whip to hold the freehub from spinning as you turn the stuck cog(s) the proper direction to free them. Cutting into the freehub splines happens with lightweight alloy (aluminum) hubs. It's not a warranty issue. I have an American Classic freehub that does the same thing.
Clean up the cassette and hub, reassemble, and see if your creaking goes away--but, I doubt that is the origin of the noise.