well I ended up getting a brand new wheel from Specialized so I will not be opening the freehub anytime soon after all ... but when you say DT-Swiss internals - do you mean the star ratchet mechanism ? or regular pawl design?
Regular M5x10mm bolts are too long for the rear hub/motor assembly, the spindle stops spinning way before the bolt bottoms out.
I had my wheel replaced by Specialized (bad torque sensor) and after stripping a bolt on the original wheel when swapping them out I left the rotor and the bolts on...
spokes are fine after the wheel rebuild, brass nipples and stronger spokes laced to wider rim stopped the nipples breaking.
But now it's time for the hub itself, the freehub mechanism, sounds rough ... am going to regrease the pawls sometime soon.
I got 4k miles on that hub
and based on 1 year and 4k miles I am not holding my breath ... Specialized has been a total chaos when dealing with things like faulty control unit, bad battery or a complete wheel rebuild ... good thing the dealer steps up as much as they can.
It's time for a complete overhaul of the bike after 4k miles. I just finished replacing the drivetrain and had the rear wheel rebuilt (factory spokes / nipples are POS)
What I would like to do next is to rebuild the hub, does anybody here have any experience with that? What kind of pawl system...
my bike is currently at the shop for this: http://electricbikereview.com/community/threads/2015-2016-base-turbo-startup-issue.3720/
Shop was able to repro it and verify it's the battery, currently waiting to hear from Specialized while I ride the identical loaner (minus the rack and brooks saddle)