Originally Posted by
Dan333SP
I have a 2013 Madone with the same issue, I know it's the headset bearings because eventually rust started coming out of the gap between the fork and the headtube, and if left overnight after a damp ride the bars won't rotate at all unless you give them some force and get the bearings moving again. It now presents itself as a clicking just like you describe.
Unfortunately for me, the Madone has integrated angular contact 1 1/2" to 1 1/8" cartridge bearings. I've dropped the fork and greased everything so that the bike can still steer, but the upper and lower cartridges are basically shot and need to be replaced.
I emailed Trek for exact measurements on these bearings after buying a set I thought would fit with no luck. They told me it's impossible to know the exact measure without having the bike seen by an authorized dealer, and they need a special tool to remove the bearing race on the fork crown.
That's confusing for me because it looks like they're just 2 cartridges that sit in molded grooves, and I gave them my model, year, size, fit type, and serial # so you'd think they would be able to give me information on replacement bearings. Oh well, guess I'll end up swallowing my pride and having a shop do it for what will probably be $100+ on a job that shouldn't cost more than $20.
Do the bearings not pop out? The bearing measurements and replacement part number is usually etched on the side of the cartridge. If they are seized in the cups just bang em out from behind with a headset cup remover. Squirt some penetrating oil in the and let it soak if necessary. You also shouldn't need to replace the bearing race unless its damaged.