I have a "12 speed" carbolite model peugeot that i have pulled apart.

The headset bearings were 5/32 but had some play in the headset when i got the bike. The top was a caged bearing and the bottom was all looseball.

All the bearings i pulled out, loose and caged were 5/32s
I put in all new looseball in the bottom and that appears to be perfect but for the top race they dont seem to fit. I am wondering if they ran bigger balls in the top vs the bottom? The top race doesnt want to sit perfectly over the bearings properly which is what is causing the play. I have no idea what model headset this is but chances are it is orginal to the bike. I will try to take a picture of it if that helps.

I am just wondering if someone put the wrong sized bearings in there to begin with prior to me getting it. At this point i need to know what size should be in there or if i should give up and spring for a new Tange Levin provided the french frames were not some sort of proprietary size that i have to use some kind of french headset.

Did you, by chance, put the caged balls in upside-down? I have an '84 PH10 and the head set still works perfectly (as does every thing else).
Jon

Nope tried it both ways just to be sure. I was able to get loose ball to work and get it adjusted correctly with no slop. At first i thought it was binding but the tolerance between being a bit loose and binding was so so so small i thought something was wrong. IT just took many many tries to get it spot on. I have never had one that fussy. Strange headset....but i did use 5/32 on the top and bottom

The wheels for this frameset are shot and have heiliomatic hubs so i need to search out another wheelset. I have a couple 10speed wheelsets but i am not sure i want to go 10 speed. I was thinking 8 or 9. Time will tell i guess.

....they were, mostly. Don't know about yours exactly. The tubing diameters were all metric, so the sizes for clamps and headsets are different, and the threading on the fork is different too. Velo Orange was selling a French headset for a while. You can check on their website. Otherwise, French stuff shows up on the French version of E-bay, and Amazon.

When a bike like that gets old enough, It can be difficult to figure out the mechanical history. Someone before you might have swapped out one of the races, etc.

Measure the crown race seat on the fork before you buy anything. Some of these had a larger crown race seat diameter as well (27.2 or something equally unexpected.)

Thanks. I did get the stock headset sorted out. IT was fussy but it is done. Time will tell if it stays put. On to find a wheelset now. I do believe this a PH 501 so mid range from what i gather. NIce frameset.

Scale
You have a PM.
Jon T.

Glad to hear that the OP got this sorted.

I had a similar situation after meticulously rebuilding the old Shimano 600 headset on a 1981 Bianchi just a few weeks ago. What was odd was that I adjusted the headset with a dummy stem in place to simulate the expansion of the quill in the steerer. I had it perfect and with the locknut good and tight, but after the first ride the headset had a loose adjustment! No, the locknut hadn't loosened at all, but apparently the bearings settled into their grooves a little better(?). Weird is all I can say, but I can say that I've seen these things happen, somehow.
Perhaps the cups or crown race finally settled more fully onto their press fit, even though the old bike was used and I hadn't disturbed the press fits at all during the rebuild process.

On the other hand, In 50 years I have come across a couple of headsets that were poorly machined such that one pair of the properly-assembled cups and cones rubbed slightly because of zero clearance, even with the correct size balls in place.

Oh, and on my own PH501, those headset components were HEAVY in the extreme, which is odd in that the entire bike weighs only a bit over 22lbs iir.

I dont know how much more heavy this stock headset is than any other headset i have used. IT seems pretty simular to just about every other headset i have used. A few grams in either direction isnt noticeable at all. I figured if the headset didnt go back together or if it was worn i would replace but i didnt take the crown race or cups out to measure them. I figured more than likely they were some weirdo french sizing and id just be wasting my time trying to find something else. I am glad these worked out. Like i said...had they not......the whole thing would have came apart and i would have started searching for a replacement. I have had really good luck with Tange Levin headsets. The price is right and they are quality. I just dont know if these are standard sizes in this peugeot. If i had my choice this is what would replace the stock headset.

Scale,
If you're not going to use the Helio system and the cassette is in good condition, I'd like to have a back up if you want to part with it.
Lemme' know.
Thanks
Jon

I will let you know once i get my wheels. Both the hub and cassette are in great shape. Chances are i wont ever use them.
Once i get replacement wheels i will let you know.

Thank you, Sir.
Jon