So, I don't know much about headsets. I just got my frame back from being repaired and the Griplock cap from the NoThreadSet (2008ish) is stuck at the top of the fork. Do I need a tool to push this thing down? It seems very very tight and I don't want to damage the steel steer tube by forcing it down. See pics.

Thanks.

How did it get up there, did you cut the fork down? In any case you can push it down with any sort of punch. But before you do so, see of your cap screw is short enough to allow the cap to be tightened against the end of the fork.

This is the acid test, since in use the cap will need to be tightened until it's not quite touching the fork (1-4mm gap). If you can bottom out the cap, that's farther than you'll ever need to so you're good to go.

Burrs left inside the steerer tube , I see, so there may be also burrs on the outside.
remove the part in the top picture and clean up the cut edge to remove the burrs .


a 6" long half round file should be the tool to use..

though a Carborundum grit paper or cloth and a wooden dowel and flat stick

as a backing for the abrasive will Do.

It's up there because I removed the top cap/screw/stem and sent them the frame/fork. They removed the fork and stuck the Griplock cap on the top of the fork, then packaged it up and sent it to me like this. The fork is the same length so everything should fit back fine.

Since I don't own a punch, it there some other common tool I could use? I suppose I could go to the hardware store but they're closed today. Or best to head to the LBS? Obviously, I'd prefer to do it myself. Thanks.

I don't know the installation procedure for a Griplock cap, but I doubt it involves the use of a punch. The Griplock cap should probably be removed so the problem can be assessed and corrected -- by you or a shop.

Burrs on the outside of the steerer is a good guess.

OK, I'll remove the cap and try to get rid of burrs. It comes off fairly easily, but won't go down (by hand) further than flush with the top of the steer tube.

Chris King headset parts fit snugly all over.

If it was my bike I'd take some emery cloth to the whole outside of your steerer tube.

File or grind the outer edge of the top of the steerer tube a bit, and put some lube on the "o" ring inside the cap. Then carefully work the cap down the steerer tube - don't use a punch (Jeez, it's a quality component). I have sometimes with King headsets used a crown race setting tool and Park crown race installation tool to work the cap down. The issue is the King headset is built to greater tolerances than most steerer tubes. I just installed one on a Soma Smoothie Stainless Steel frame with a Ritchey fork and had to perform quite a bit of prep work on both the headtube and fork steerer to obtain a proper result.

PS: The star nut looks crooked in the steerer tube which will cause other problems with the headset/top cap/adjustment.

looks like your steerere tube was cut with a pipe cutter? i prefer to not use a pipe cutter on bike parts

https://chrisking.com/headsets/hds_gnut
this is grip nut, its for threaded forks, I have one on My Bike Friday..

you have a threadless fork , that is the appropriate piece for those.
https://chrisking.com/headsets/hds_nts

Griplock cap? IDK. see none mentioned here? https://chrisking.com/tech/tech_headsets

Guys, thanks for all of the replies. I tried to smooth out the top of the steerer, then used some steel wool to remove some of the rust. I got it past the top by hand but then it stopped again after an inch or so, most likely due to the remaining rust and the tight tolerances mentioned above.

So, I used a hammer to lightly bang down each side and it worked like a charm. Was it an elegant solution? Not at all. But it worked without breaking/bending the cap. I just hope I never need to get that thing off again!

p.s. I didn't see the lube recommendation until after I used the hammer.....next time.

To remove that race, just remove the top cap, stem and spacers and the tap on top of the steerer tube with a rubber mallet. That will drive the steerer down so you can get under the race and pull it up.