Just for info, and in case it helps anyone else in the same position in the future (because that's what forums are for
), the wheel is back on the bike. I got a locking nut from my LBS to replace the one that was snapped in two on the free hub. I greased the bearings in there, and tightened it up to what "feels" right. Not an easy thing to do, and something that took a bit of fine tuning. I nipped the disc side end cap up finger tight and hoped for the best. One thing I did do was to grease the pawls inside the free hub, but found that it wouldn't spin freely as the grease was creating too much friction. So I removed the grease and used some light oil instead. That seemed to do the trick and the hub spins ok now. 30 miles later and all seems well
