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My rear axle is threaded and has threads all the way out to the end. When it sits in the aluminum dropouts, the threads make grooves in the aluminum over time and i think they have caused a clunk sound when the axel is not under pressure and is rotating. i think It does this cause the axle threads are skipping back and forth between the grooves it has created. Its not loud but i can feel it when i am off my bike and guiding it to my truck or inside my house.

Anyone else expereience this? I tried filing/smoothing out the aluminum in the drop-outs to see if it would stop but no luck. the axle threads just made new grooves.

this only happens when i am not on the bike (no pressure on the axle) and am guiding it through my house or to my car etc.

Any thoughts.

I have just recently overhauled my rear hub do to a loose freehub lockscrew inside the hub, and i did notice a "minor" warped feeling when screwing in the freehub lock screw back into the cassette.

Again, any thoughts.

Maybe I might need a new rear hub? or rear cassette?
 

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Assuming the quick release is tight, there shouldn't be enough force to move the axle relative to the dropouts when walking the bike. I would look elsewhere for the noise source.

If it started right after your free hub overhaul, I suspect that's where the problem lies. If it has loose ball bearings, check for the correct number and the condition of the balls and races.
 

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if this is a quick release hub, you have the overall width of the hub set wrong, or possibly the axle offset to one side so the quick release is not able to tighten properly- it is tightening against the end of the axle instead of against the drop out. Remove the skewer, set the wheel in the frame. Does the axle protrude on either side of the dropouts? It should be just less than flush.
 
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