Kansei said:yep. the washer is still.. yet the shaft spins freely.
I think at almost 82k miles, with three rochester winters, and this being the fourth time I've had my suspension apart like this, they've just given up on life. Luckily on the other side, the washer gave up when I was tightening it back down, and I managed to get it pretty tight.
Yeah - that flat spot rounds off pretty easy (ahem). Do you have a tap/die set? I had to slightly angle the washer and "wedge" it in the threads to get things apart last time. I chased the threads with a die and got them back into shape. I small triangle diamond file (and a good amount of patience/time) will get the same result.