Originally Posted by
3alarmer
...where we disagree is on whether the degree of preload is a contributor. As stated, I'm doubtful that it is.
I'm with you there. As long as preload is within a reasonable range it doesn't make a difference. The best evidence is that fretting is almost exclusively limited to the lower stack. If preload were a factor, especially excess preload, we'd expect to see more fretting in the upper.
IME - what's happening is a combination of classic fretting, plus the effects of front end weight and vibration hitting the lower stack harder because the upper only has the preload and not the other factors. I also sense that I see faster failures with loose headset, but that's only a gut feeling.