DT Swiss Freehub slipping

I have DT Swiss EX1750 wheels on my bike, I believe they are the dt swiss 240 hubs.
They've been trouble free for years. I've just popped the freehub off, cleaned the pawls, fresh grease (got the official dt swiss stuff) all fitted back fine.
When riding if I rotate the cranks backwards a little then forwards the freehub doesn't engage at all, then after a good few turns it does.
I've tried taking it apart again and double check its all going back together properly and still the same issue.
What could be the problem???
If the freehub is worn (any tell tale signs to look for?) do I have to replace it with a DT swiss, or can i mix'n'match i.e put a shimano freehub on ?
They've been trouble free for years. I've just popped the freehub off, cleaned the pawls, fresh grease (got the official dt swiss stuff) all fitted back fine.
When riding if I rotate the cranks backwards a little then forwards the freehub doesn't engage at all, then after a good few turns it does.
I've tried taking it apart again and double check its all going back together properly and still the same issue.
What could be the problem???
If the freehub is worn (any tell tale signs to look for?) do I have to replace it with a DT swiss, or can i mix'n'match i.e put a shimano freehub on ?
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Parktools :?:SheldonBrown
I'll clean it all off and start over....will update in a bit
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Thanks Nick
Shop here....eBay Shop
240s have 'star ratchets' which are more like clutch plates.
+ some other bikes.