I've just come to replace the bearings in my XC freehub and the new ones seem to be loose on the axle. I've got both no-brand and SKF bearnings so I think I can rule out poor tolerances on the inner race. Could the axle have worn? If not, will loading "pick up the slack" as it were, when its on the bike.

Ring Hope. I bet they'll send you a new one. 🙂