Oh. Are you installing the old bearings? That, plus damage to the spacer tube, will be why you’re getting bad results.
As for freehub servicing in general… most manufacturers consider the freehub to be a non-serviceable item. This is most commonly seen with brands using lightweight and soft aluminium materials, where removing the bearing (badly) can cause the freehub itself to ovalise or the bearing seat to stretch out. Add in that the pawls and freehub splines tend to wear, and you have a part that many brands just suggest you throw away rather than fix. That said, I’ll certainly replace the bearings in freehubs whenever the rest of the part is still workable.
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I re-packed the old bearings as they were not BAD to start with and felt ok after regreasing BUT since I needed new hub bearings anyway, I ordered the freehub ones for backup.
Having been through this repair debacle and searched for new formula freehubs I now know why my LBS mate declines to work on formula hubs at all. 
Yep, Formula hubs can be really tough to find spares for.
Just for those playing along, I’d strongly advise against ever pulling out a hub bearing unless you plan to replace it (unless it’s something awesome and expensive like an Enduro XD-15). The press-fit surfaces do wear, so pulling and re-installing already worn-out bearings will only shorten the lifespan of the whole component.
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Good point, noted for future, thanks Dave.
This wheel is rather unloved 3rd set for my CX bike so it was a conscious decision that I just wanted to get it serviceable again. You shoulda seen it last week when I put these wheels on for the first time in 6 months - it would hardly turn because the left hub bearing was rusted solid. I managed to scoop the seals out and work some oil into it and then some grease just so it’d work for the weekend. I wish I could see your face now. 
The only bearings I’ll pull and ‘service’ are the Ceramic speed ones that are fitted to some Hunt hubs. I really don’t see the benefit in having ceramic bearings in the freehub but if they are running smoothly, I’ll repack them with the CS grease.
All other bearings get pulled, chucked and replaced with Stainless bearings.
The absolute worst have to be the freehub bearings in many Fulcrum/Campagnolo freehubs which only have a seal on one side. Penny pinching madness as these fail really quickly if the bike ever sees any wet weather.
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