I had an XT (770, 9-speed) hub fail on me about a month ago when the freehub seized. Since it was under warranty, I shipped it back to the shop to have them deal with it (I don't have a 14mm hex wrench).

I got it back today and it spins fine without the cassette, but when I put the cassette on (XT 770 9-speed too) and tighten it, the freehub is completely stuck. When I loosen it, it frees it up, but the cassette is definitely way too loose. I'm not using a lot of force at all, and it starts to stick when I still have at least 3-4 rotations before the lockring is snug.

Should I send it back? Am I doing something wrong? Thanks.

Also, I just noticed that the hub no longer has the seals on it. Should I complain about that as well?

There may be a washer missing from behind the cassette.

I agree, closkey-OP, is the cassette touching the actual body of the hub? Might need a spacer in there.

i just put a 1mm spacer on the freehub, and it pushed the cassette out too far that i can't get any threads on the lockring to engage.

i cant see anywhere where something might be rubbing/touching. the axle doesn't spin either when i tighten the cassette down.

Send that back. You don't need ANY spacers for a 9s cassette on a 8/9 XT rear hub. Something was probably assembled incorrectly or incompatible parts were used.

Shimano freehubs may have some incompatibilities with the seals - if they tried to substitute not the original spec freehub on it. Or they tried to hack fix it to make it fit.

thanks. i probably should have mentioned that i was using this combo before the freehub failed and i didn't have this issue.

what's lame about this whole scenario is that i had my miyata 1000s (touring bike) rear dropouts spread to 135mm to use "bombproof" XT hubs (velocity synergy rims). the freehub failed after 16 months of gentle commuting in san diego. i wish i would have left it at 126 now.

Don't tell Shimano this part, "misuse of component". Don't want to give them any excuse to back out of the warranty.

Bent axle, maybe? Could be binding things up, both when you tighten the cassette -- the lockring tool will bind inside a bent axle under those conditions -- and when the wheel's on the bike -- insufficient clearance between cassette and axle locknut.

Worth a look......

I can freely remove the lockring tool during various stages of tightening. When it is removed, the hub is still stuck. I don't have the wheel on the bike, let alone skewers or even the tire.

.
You're not reading my post correctly. You sent the hub back for warranty right? The repair could be performed incorrectly

i was responding to dx-man.