Originally Posted by
joejack951
If your mechanic has a thread file, he could use that to clean up the threads in the freehub if one is nicked or if the minor/major diameter of the threads is bad. He's more likely to have the thread file than the correct size tap
He had a sharp "pick" tool and ran it around inside the threads of the freehub body...mostly to explore and see if there were any obvious signs of damage. He said he didn't really see any damaged threads on either the freehub body, or the cassette lockring. But it was still not possible for him to get the lockring to thread in more than 1/8 turn (without applying mechanical force).
This is consistent with the email I got from Zipp that it's a "manufacturing tolerance" issue in their hub, and not the result of damaged or mangled threads.