The $4 shim trick that finally got my rear derailleur dead silent on a 1994 Rockhopper
Had a customer's old Rockhopper in the stand for a week with a ghost shifting problem I could not pin down. New cable, fresh housing, hanger aligned twice, still skipped under load in the middle cogs. Turned out the cassette had a tiny bit of play on the freehub body, so I cut a shim from a soda can and slid it behind the cassette. Two thousand miles later the guy says it shifts cleaner than his new bike. Anyone else run into freehub play causing ghost shifts, or is it just these old Shimano hubs?
The freehub body itself can wear where the cassette cogs dig in, and that's often the real culprit on those old Shimano hubs. When the splines get notched, the cogs rock side to side even with the lockring cranked down, and no amount of cable tuning will fix it. A soda can shim buys you time, but check those spline marks next time, because if they're deep you're just masking a hub that needs a new freehub body.