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@croft
Cheers for the suggestions @RainbowBungle @Sam @jj72 - still not figured it. Pawl springs return ok by hand. I've take the wheel out of the frame and removed the cassette so that cuts out those options. It's only in about half of the positions of the freehub body against the splines, it's audible and perceptible by feel too, like a judder.
Putting the wheels on a new frame this week so will get the mechanic to check it out.