One bug way to have problems with Shimano freehubs, not setting the bearings correctly and not cranking down the QR. They don't like flex, things start coming loose.
FYI actually bearing preload can effect the freehub. Ever taken a Shimano freehub apart? I have, more than once. Freehub bearings being too loose or too tight (there is shims behind the axle bearing cup and the outer freehub bearings ride in there) can cause issues.
Too thick of grease causes skipping which leads them to snap pawls.
Crap pedalling technique will snap the pawls (jamming down while pawls aren't engaged) which is likely the most common cause.
Have skewer/axle loose plays havoc on makes the hubs come loose, flex and eats the the freehub body.
Don't get me wrong, design could be done better, but it's often a set up issue or ride technique issue that takes them out.
275lbs geared, hard on my stuff, 3 yrs on slx hubs. Due to getting caught in a storm with bike on the back of my car, I had to service them to be safe. Didnt havre the wheels a month. Marine greased everything. Made sure everything was set correctly, never had to touch the hubs again. Still in perfect shape in February this year (2 months shy of 3 yrs).
But last set of wheels I built are on BHS hubs (fat bike). Great budget hubs. Now my go to for any hubs I need.
PS:. 275lbs on a Shimano road bike hub, full year, getting beat plenty especially now with 1x11, 0 issues at about 1000 miles or so. Plenty of hill mashing.
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