fholt

I serviced my shimano hub bearings this afternoon, it's a Tiagra rear freehub, and I just did a clean the cups, fresh grease, and replace the ball bearings kind of service. I took apart only the left side, removed the axle from the freehub side, then repacked the grease, placed new bearing balls, and reassembled from the left side. Adjusted just the right tension on the wheel bearings, remounted the tire, and ready to roll (and it does roll good).

However - when I remounted the wheel in the frame (without cassette or chain) the freehub stays stationary when I spin the wheel forward. Seems it should turn freely with the wheel without a drivetrain to keep it still. So, I'm guessing I've introduced some drag from the axle or right side dust cap, etc. What's the likely scenario? What did I do wrong?

FBinNY 

You didn't bugger it, you probably did too good a job. Check by touching is as it spins. If only a light touch is needed to make it freewheel it's fine.

What's happening is that the viscosity of the full grease pack in the right bearing is greater than the friction of the freewheel ratchet, so the freehub body stays stationary. With a bit of riding grease will be pushed aside leaving only a light pack in the bearing, and the hub will act the way you expect.

The other possible cause of excess drag is a seal rubbing a bit hard, but that's more common in new hubs than rebuilt ones.

BCRider

Another thought is that some of the excess grease from the right side cup may have squeezed out onto the axle, which doesn't turn, and is lightly holding the freehub to the axle. Again this will soon sort itself out once you start riding. As long as you can still easily spin the freehub and cassete all is well.

jccaclimber

If you buggered your dust cap on the drive side of the hub then you'll have a bit of drag there until it wears away. Otherwise, as suggested above if it only takes a light touch to fix things, then don't worry about it.