tommyd49

Hi all. I'm trying to clean out and regrease the (threaded) headset on an old steel frame bike I'm working on. I've loosened the locknut, but I'm having trouble removing the keyed washer. The open slot in the steerer that the washer's key sits in seems to stop about 1/8" from the top of the steerer (see pictures), so I can't just pull it out easily. I've tried lifting at the opposite side to the key first, but I can't get any part of the washer off the steerer tube. Does anyone have any ideas on how to remove these things in this situation? I suppose I could just file the bit of thread above the slot, but it begs the question how was it installed in the first place!

dsbrantjr

Would you be able to remove the washer if the tab was bent downwards a bit?

_ForceD_

How far down the steerer tube does the slot go? I’d be concerned that if you cut that 1/8 inch at the top away that you might lose the tube’s integrity or strength to keep the steerer tight in the tube.

Dan

Andrew R Stewart 

Do not cut down the steerer or open the slot to the steerer's end! This type of slot is fairly common on older moderate/low cost bikes of the 1970s/1980s. Your second method of trying to remove the washer is what works although sometimes a fair amount or pry action under the washer, opposite the tab, is needed to lift it off. Once off file down the tab and don't bother trying to use it's being in a slot during the tightening down of the top nut. Andy

tommyd49

I can try, but I think I might struggle to bend the tab down because it's quite thick (see attached photo).

I might try and use more force this time when trying to pry the washer to the opposite to the key. I was quite gentle last time. Just hope I don't damage the threads on the steerer at all.

70sSanO

Since it is a brake hanger, I would probably take a little off the tab and maybe work the ID just a bit to make it is easier to install/uninstall.

John

_ForceD_

Maybe you could try this...
with a drill bit no bigger than the width of the slot...working from the inside of the tube, through the slot...you could drill that tab off.

Dan

Moe Zhoost

I'd tackle this by gently tapping sideways at the brake hanger end to ensure that the small key tab is not bound up in the slot, Once you know it's free, tap gently on the bottom of the brake hanger end until it resists moving. Then tap up on the opposite side (a small block of wood may be handy) see-sawing back and forth until the thing pops off. The key is to not force it, but instead to gently coax it to climb the steerer tube. Stay away from cutting tools lest you damage the threads.

Good luck.

MudPie

I’m curious as to how it was initially installed!

alcjphil

Me too. Somebody managed to install it so it must be possible to remove it

Dan Burkhart 

Maybe it's one of those brain teaser puzzles.When the solution comes to you, you probably will have no idea how you did it.

AlanO

They get bound on the steerer threads when the locknut is tightened, it’s just jammed. The hole that fits over the steerer is large enough that you hold it at an angle, slide the tab into the slot, then lower the other side. See if you can see which side of the slot it’s jammed on and whack it with a rubber mallet, not plastic. It should pop off. When it’s loose lift the side without the tab first. Reassembly is the opposite. Make sure to check the thread for damage before reassembly.

tommyd49

So, I had another look at this today. I don't know what I was doing last time, because today I was able to easily remove the washer(s) with just my fingers! Turns out there were two rather than than just one - which meant they were both thinner than expected. It did help to push the tab side up first, hold it there in place then push up the side opposite to the tab (see video here).

What I have exposed underneath is a bit strange - a separate, very thin locknut on top of the adjustable race (no wrench flats but with a pattern that allows grips to be used). See the picture below. This is as well the big locknut that sits above the keyed washers. It is a Tange Unique X headset - not sure what exactly to do with this one...

tommyd49

I had a Google and luckily managed to find an instruction manual for these here. Still, seems quite an unusual design - at least to me. Anyone come across these before?

madpogue 

And yet another nut beneath that knurled one. That does seem like an unduly complex stack for a threaded headset.