I noticed that my rear wheel had some left to right play on the axle but tightening up the axle prevented the freehub spinning. After removing the freehub I discovered that the freehub body washer was bent out of shape, causing the the freehub to kink when the axle was tightened.
Its a Merlin hub and I cannot find a replacement on their website and the original is too bent to take measurements off to buy a different brand.
I don't see what the washer is actually doing, there is a spacer on the axle which keeps the freehub body away from that part of the hub. Is it safe to use the freehub without the washer?