Ratcheting Hub Noise?

[Vexy]

I recently replaced my wheel bearings and spindle on the driver side. Now, when driving with the Warn Manual hubs "unlocked", it makes a rather obnoxious ratcheting noise. But when you "lock" them, the noise is no longer present.

What could be causing this?

PS: If this helps, we had to pry the axle with a bar to have enough room to put on the c-clip. I don't know if that would cause a problem...

Any input would be appreciated!

 

[Hahnsb2]

Have the wheelbearing nuts come loose? New spindle fully seated on the knuckle?