Hi folks,
I'm overhauling my '73 Schwinn World Voyaguer. I've run into a bit of an issue trying to take the headset apart. I removed the lock nut, no problem. Now it seems like the spacer between the lock nut and the cup (other nut) is stuck. I realize there is a little tab on the spacer and it looks like it is in the slot like it should be. But I can't get it off. I tried sliding thin objects underneath such as a razor blade and gently tapping with a sharp chisel underneath, I also sprayed some liquid wrench around the area. I definitely don't want to do any damage so any insight would be appreciated, maybe i'm missing something that should be obvious. BTW, I also just disassembled the bottom bracket and had a heck of a time getting that lock nut off as well, though I did get it off. Thanks in advance

Pictures below

a couple poor pics. if they help:

You've anticipated what is the common problem with headset lock washers. The anti rotation tab gets jammed on the threads because the washer gets slightly rotated off it centered position. The first thing I'd try is to grab the washer with a pair of channel lock pliers and rotate it on the steerer. If the tab was off center it will kind of set in place when the tab and groove line up. Then the next thing i do is what you have already done. Try to pry it up with a knife edge driven under the washer. Often you can get the tab to skip over a thread and this then lets you know that the washer needs rotating. Sometimes the tab is taller/deeper then the groove is and is hanging up in the groove. prying the washer up is the only real option here. When off a slight filing down of the tab usually fixes this. BTW when you reassemble it don't rely on the tab to keep the threaded cup from rotating, use two head set wrenches during the tightening. Andy.

Thank you very much I will have to mess with it tomorrow. Is it likely that the anti rotation tab might damage the threads if it is a bit out of place?

Yes, if the tab is stuck in the threads there will be some damage. But you have to look at the totality of the situation. There are a lot of clean threads left around the vast majority of the steerer. Also when the threaded cup is removed and reinstalled it will, to a degree, clean up the small spot of damage. So go ahead and pull off that washer trying to be careful but knowing that a small amount of thread crushing is not a problem that will cause any real issue. Andy.

Been through this with many types of threaded fasteners before. Andrew's got you covered here, and if needed you can use a needle file to gently reshape any mashed threads. A die would work as well, but could get hung up on the vertical slot, and most people don't have one in that size & thread pattern sitting around.

thanks you guys!

Ok i'll confess, even though I feel a little dumb, there was no tab on the spacer. It was threaded on, I tried to turn it with the channel locks as suggested by Andrew and with a fair amount of force it turned. There is a brake cable hanger that came off first that had an anti turn tab on it. I obviously thought the spacer/washer had one as well (it sure looked to me like it did but I guess I was just seeing the threads). Oh well, I guess it's better to proceed with caution and ask questions than to screw something up.

I've come late to the discussion but I immediately saw that it was a threaded spacer...even with the bad picture. A hook spanner is what you need to remove the spacer. Unfortuneately, a bottom bracket hook spanner is usually too large. It will work but it isn't the best tool for the job.

Photo note: BACK UP!

Yes it should have been obvious, but oh well, sometimes that's the way it goes, I would much rather ask a dumb question, or walk away from something i'm unsure about for awhile than destroy my headset or steerer tube. I actually made the mistake of turning a washer that had an anti-rotation tab once. I did that on a Schwinn Varsity, my first overhaul, it ended up going back together fine but that is why I am so cautious about it now, this bike is much nicer than a Varsity. As far as the photo note, thanks, I'll keep that in mind.

I'm not saying that it should have been obvious to you. If you have seen these headsets before, they are immediately recognizable. They are a weird design and I was never sure why they were used. It's a belt, suspenders, duck tape, staples approach to headsets. The lock nut and the threaded cup are all that are necessary but, for some obscure reason, the middle ring was added. It's a dumb design.

The anti-rotation washers often turn on their own and get jammed in the threads. They are buggers to get off. Been there, done that.

Or use the camera's "macro" (close up) focus setting. Most have them these days.

oh ok, thank you. Yes it is difficult when things are put together many different ways.

Good catch. One of these ought to do the job: