2016-2018 FLOAT X2 Rebuild

Required Parts

  • 803-00-951 Seal Kit: Float X2 Spring and Damper Rebuild 2016-2017 all sizes except 8.75x2.75
  • 803-01-147 Seal Kit: FLOAT X2 Spring and Damper Rebuild 2016-2017 8.75x2.75 and all 2018

Required Tools

  • 027-00-013 Pump: Fox Digital HP w/ Bleed, Foldable, Replaceable Battery, 300 psi
  • 213-01-460 Eyelet: 9mm Shaft, DHX2, Increased Clearance
  • 398-00-280 Tooling: Eyelet Torque Tool
  • 398-00-418 Tooling: 2016 Float X2, Bullet Tool
  • 398-00-419 Tooling: 2016 Float X2, Negative Air Seal
  • 803-00-463 Kit: Fill Machine Adapter, 04-07 Epic IV, DHX Air, RC2_RC4 Shocks
  • 803-00-566 Kit: Bike IFP Depth Setting Tool Set
  • 803-00-967 Kit: Tooling: Shaft Clamps, FLOAT X2, 9mm Shaft
  • 803-00-968 Kit: Tooling: Clamps, FLOAT X2, Air Sleeve
  • 803-00-969 Kit: Tooling: Clamps, FLOAT X2, Body--------- ---------(Only needed if replacing the outer body)

Supplies Needed

  • 11mm 6-point socket
  • 14mm 6-point deep socket
  • 2mm Hex Wrench
  • 6mm Hex Wrench
  • Ratchet
  • Seal Pick
  • Strap Wrench
  • Torque Wrench
  • Waste Oil Basin

WARNING: FOX products should be serviced by a trained bicycle service technician, in accordance with FOX specifications. If you have any doubt whether or not you can properly service your FOX product, then DO NOT attempt it. Improperly serviced products can fail, causing the rider to lose control resulting in SERIOUS INJURY OR DEATH.

WARNING: Never attempt to modify air volume spacers, as this can damage your shock causing a loss of control of the bicycle leading to SERIOUS INJURY or DEATH.

WARNING: FOX suspension products contain pressurized nitrogen, air, oil, or all 3. Suspension misuse can cause property damage, SERIOUS INJURY OR DEATH. DO NOT puncture, incinerate or crush any portion of a FOX suspension product. DO NOT attempt to disassemble any portion of a FOX suspension product, unless expressly instructed to do so by the applicable FOX technical documentation, and then ONLY while strictly adhering to all FOX instructions and warnings in that instance.

WARNING: Modification, improper service, or use of aftermarket replacement parts with FOX forks and shocks may cause the product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork or shock, including the fork brace (lower leg cross brace), crown, steerer, upper and lower leg tubes, or internal parts, except as instructed herein. Any unauthorized modification may void the warranty, and may cause failure or the fork or shock, resulting in SERIOUS INJURY OR DEATH.

The Damping Adjuster Cartridge Assemblies should be considered non-rebuildable as they are difficult to dissassemble and reassemble. The Damping Adjuster Cartridge Assemblies do not need to be removed from the shock to perform a full rebuild. If damaged, please replace as complete assemblies.

 

For instructions guiding you through the removal and reinstallation of the X2 Damping Adjuster Cartridge Assemblies please go to: X2 Damping Adjuster Cartridge Assembly Removal/Installation »

 

For information regarding the X2 2-Position Lever please go to: FLOAT X2 and DHX2 2-Position Lever Upgrade »

The following procedure guides you through the full rebuild of the FLOAT X2 shock.

 

Complete part information and technical drawings for FLOAT X2 shocks can be found by clicking: FLOAT X2 Part Information »



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Step 1

Set all rebound and compression adjusters to their lowest setting (fully counter-clockwise).

Clamp your shocks non-adjuster eyelet in a soft-jawed vice. Remove the black air cap and thread on your FOX shock pump. Slowly release all air from the main air chamber with your pump, then remove the pump. Verify that all air has been released by depressing the Schrader valve with a lint-free towel covering the valve to prevent any oil spray.

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Step 2

Rotate the air sleeve counter-clockwise (when viewed from above) until it stops, then push it down toward the soft-jawed vice. There will be resistance as you slide the air sleeve down due to o-ring friction. Remove the shock from the vice and slide the air sleeve the rest of the way off the shock to remove.

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You may rotate the adjuster eyelet independantly of the non-adjuster eyelet at any time to help create air valve to piggyback clearance.

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Step 3

Remove any air volume spacers by stretching them over the non-adjuster eyelet.

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Step 4

Clean the inner air sleeve with isopropyl alcohol and a lint-free paper towel. Clamp the inner air sleeve in your X2 air sleeve clamps (PN: 803-00-968). 

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Step 5

Carefully engage the prongs of the negative air sealhead tool (PN: 398-00-419) with the notches of the negative air sealhead. Do not scratch the outer body with your tool. Maintain downward pressure on the negative air sealhead tool to keep it engaged while you turn it counter-clockwise to unthread. Slide the neg air sealhead up toward the adjuster eyelet once unthreaded.

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Step 6

Invert the shock in your clamps, then turn the eyelet torque tool (PN: 398-00-280) counter-clockwise to unthread the eyelet from the inner air sleeve.

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Step 7

Unthread the inner air sleeve from the non-adjuster eyelet. Slide the inner air sleeve and neg air sealhead toward the adjuster eyelet.

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Step 8

Clean the shaft with isopropyl alcohol and a lint-free paper towel, then clamp the shaft in the FLOAT X2 specific 9mm shaft clamps. Be careful not to let any part of the shock contact the vice. Unthread the non-adjuster eyelet from the shaft by turning it counter-clockwise. 

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Step 9

Remove the non-adjuster eyelet and replace the o-ring with a new greased one from the kit. Set the rebuilt eyelet aside.

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Step 10

Remove the travel/volume spacer if present. This part can be tight on the shaft, and can require significant force to remove. Remove it by pulling up. Do not bend the shaft while removing the travel/volume spacer if present. Remove the two bottom out plates and the bottom out o-ring and set them aside.

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Step 11

Remove the inner air sleeve by sliding it off the shock. Replace the o-ring on the inner air sleeve with a new greased one from the kit. Inspect the inside of the inner air sleeve for any scratches or damage and replace if necesarry.

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Step 12

Unthread (counter-clockwise) the reservoir end cap assembly from the reservoir with a 6mm hex wrench. Remove the reservoir end cap assembly and replace its o-ring with a new one from the kit.

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Step 13

Release the nitrogen charge by depressing the Schrader valve within the reservoir. Gently push the shaft in to create clearance to access the wrench flats of the bearing assembly.

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Step 14

Use a deep 14mm socket to unthread (counter-clockwise) the bearing assembly from the body. Remove the bearing assembly and inner body from the outer body by pulling up. Drain the inner body over a waste oil basin.

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Step 15

Remove the neg air sealhead and replace all its seals, glide ring, and backup ring with new greased ones from the kit. Inspect the outer body for any scratches or damage and replace if necesarry.

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Step 16

Clamp the shaft in your X2 specific 9mm shaft clamps with the inner body above the vice. Pull up on the inner body to remove it from the bearing assembly. This part can be tight on the bearing assembly and can require significant force to remove. Do not bend the shaft while removing the inner body.

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Step 17

Use an 11mm socket to unthread (counter-clockwise) and remove the piston nut. Remove the piston and valving assembly keeping all parts in their original order. Replace the blue glide ring and o-ring on the piston with new ones from the kit.

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Step 18

Remove the bearing assembly and replace all seals and backup rings with new greased ones from the kit.

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Step 19

Install the X2 bullet onto the shaft and apply a thin film of Slick Honey to the taper of the bullet. Install the rebuilt bearing assembly onto the shaft as shown. Remove the bullet tool.

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Step 20

Reinstall the valving assembly, piston, and piston nut. Tighten the nut clockwise to 60 in-lb (6.8 Nm). 

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Step 21

Reinstall the inner body with the ports oriented toward the bearing assembly. Press down on the inner body to completely seat it on the bearing assembly.

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Step 22

Install the rebuilt neg air sealhead assembly onto the outer body with the wiper lip oriented toward the adjuster eyelet. Be careful not to fold the wiper lips in or displace the glide band within the bearing assembly during installation.

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Step 23

Install the inner body into the outer body. Thread the bearing assembly to the outer body, then use a deep 14mm socket to tighten (clockwise) the bearing assembly to 145 in-lb (16.3 Nm).

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Step 24

Temporarily install a DHX2 shaft eyelet (PN: 213-01-460) onto the shaft, tightening (clockwise) until just snug. This will prevent the shaft from being sucked into the damper during the vacuum cycle later.

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Step 25

Remove the wire retaining ring from inside the reservoir. Thread your shock pump onto the Schrader valve of the reservoir end cap, then use your pump to pull the cap out of the reservoir. Replace the o-ring on the reservior end cap with a new greased one from the kit, then set aside. Fill the ring groove on the inner wall of the reservoir with slick honey to help prevent damage to the IFP during removal.

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Step 26

Unthread and remove the set screw and o-ring from the back of the adjuster eyelet with a 2mm hex wrench. Cover the reservoir with a lint-free paper towel and inject compressed air into the port on the back of the adjuster eyelet to blow out the IFP. 

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While FOX recommends using the Andreani vacuum bleeder, the FLOAT X2 shock can be hand bled if needed. 

For hand bleed info please skip to Optional Hand Bleed Instructions » after completing step 26.

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Step 27

Replace the o-ring on the IFP with a new greased one from the kit. Reinstall the IFP into the reservoir with the counterbore facing the open end of the reservoir. Replace the wire retaining ring to retain the IFP during the oil fill steps later.

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Step 28

Thread the Fill Machine Adapter (803-00-463) from the Andreani machine into the port on the back of the adjuster eyelet. Vacuum the shock, then fill with 10wt. red oil. Set the IFP to the appropriate depth using your IFP depth setting tool (803-00-566). Reinstall the set screw with a new greased o-ring from the kit and tighten to 14 in-lb (1.6 Nm).

Shock Size IFP Height (+/-0.050in)
7.875 x 2.000 1.243in/ 31.57mm
7.875 x 2.250 1.243in/ 31.57mm
8.500 x 2.500 1.293in/ 32.84mm
8.750 x 2.750 1.343in/ 34.11mm
9.500 x 3.000 1.393in/ 35.38mm
10.500 x 3.500 1.443in/ 36.65mm
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Step 29

Remove the wire ring from within the reservoir, then grease and reinstall the reservoir end cap followed by the wire retaining ring.

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Step 30

Fill the IFP chamber to 125 psi (8.6 bar) with your shock pump, then install the reservoir end cap, tightening to 30 in-lb (3.4 Nm) with your 6mm hex wrench.

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Step 31

Unthread (counter-clockwise) and remove the DHX2 shaft eyelet from the shaft. Coat the main air seals on the bearing assembly with Float Fluid, then install the inner air sleeve onto the shock with the large end oriented toward the adjuster eyelet.

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Step 32

Reinstall one bottom out plate onto the shaft. Then install a new bottom out o-ring from the kit followed by the last bottom out plate. 

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Step 33

Clean the shaft with isopropyl alcohol and a lint-free paper towel, then clamp the shaft in the X2 specific 9mm shaft clamps with as much shaft exposed above the clamps as possible. Too little shaft above the clamps can prevent you from threading the eyelet completely onto the shaft. Do not let any portion of the shock touch the vice below the clamps.

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Step 34

Reinstall the volume/travel spacer if your shock originally came with one. This part fits tightly on the shaft and may require you to thread the eyelet on to install the spacer completely onto the shaft. Install the non-adjuster eyelet tightening clockwise to 90 in-lb (10.2 Nm) with your eyelet torque tool (398-00-280).

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Step 35

Apply 2cc of Float Fluid to the bottom out plates and o-ring. This prevents noise from the bottom out plates rattling against the shaft. 

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Step 36

Slide the inner air sleeve toward the non-adjuster eyelet then thread them together until snug. Slide the neg air sealhead to the inner air sleeve and thread them together until snug. 

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Step 37

Clamp your negative air sealhead tool (PN: 398-00-419) in your vice, then carefully rest the negative air sealhead in the tool. Make sure to engage all three prongs of the tool with the notches in the neg air sealhead. Do not scratch the body against the tool or vice. Use the adjuster eyelet to hold the shock down to maintain engagement with the neg air sealhead tool. Turn the eyelet clockwise with your eyelet torque tool to tighten the eyelet to the inner air sleeve, and the inner air sleeve to the neg air sealhead. Tighten to 180 in-lb (20.3 Nm).

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Step 38

Remove all rubber FLOAT X2 air volume spacers by stretching them over the non-adjuster eyelet. Clean off any excess Float Fluid that is coating the inner air sleeve, spacers, and o-rings. Install the Red Spacer Limiter approriate to the travel of shock you are working on as indicated by the chart below.

Update Kit PN Shock Travel Red Spacer Limiter
803-01-165 2" Stroke NA
803-01-166 2.25" Stroke 233-00-361
803-01-167 2.5" Stroke 233-00-361
803-01-168 2.75" Stroke 233-00-364
803-01-169 3" Stroke 233-00-362
803-01-170 3.5" Stroke 233-00-363
803-01-173 57.5mm, 60mm, and 62.5mm Stroke NA
803-01-174 65mm Stroke 233-00-361

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Step 39

Install the two "anti-rattle" o-rings around the red spacer limiter if present. Install one pair of 233-00-240 volume spacers for each rubber volume spacer removed ealier. Do not exceed the maximum spacer quantity listed in the chart below.

Shock Travel Max Allowed Volume Spacers (Pair of 233-00-240)
2" Stroke 4
2.25" Stroke 2 (equivalent to 3 spacers including the volume of the Spacer Limiter)
2.5" Stroke 3 (equivalent to 4 spacers including the volume of the Spacer Limiter)
2.75" Stroke 3
3" Stroke 5
3.5" Stroke 4 (equivalent to 5 spacers including the volume of the Spacer Limiter)
50mm Stroke 4
55mm Stroke 2 (equivalent to 3 spacers including the volume of the Spacer Limiter)
57.5mm, 60mm, and 62.5mm Stroke 5
65mm Stroke 3 (equivalent to 4 spacers including the volume of the Spacer Limiter)
70mm Stroke 7
75mm Stroke 5

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WARNING: Do not remove the internal red spacer limiter and under no circumstances use more than the Fox Factory specifed quantity of volume spacers for your shock absorber. Never use the black rubber volume spacer rings, only use the FOX orange plastic volume spacer pairs.

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Step 40

Note the tab on the inside of the air sleeve and the keyhole in the non-adjuster eyelet. Align the tab on the air sleeve with the keyhole in the eyelet, slide the air sleeve fully onto the shock (air valve end first), then rotate the sleeve clockwise (when viewed from above) until it stops.

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Step 41

Attach your shock pump then add air while you slowly cycle your shock through 25% of its travel 10 times as you reach your desired pressure. Reinstall the black air cap.

You can find additional information regarding setting air pressure by going to: Using the EVOL Air Sleeve »

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Dyno test all functions of the shock to verify proper performance, then clean the exterior of the shock.

If you have performed a vacuum bleed with the Andreani machine, you do not need to continue with the hand bleed steps below. If you intend to perform the hand bleed shown below, you must start with your shock as configured in step 26

Optional Hand Bleed Instructions

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Step 1

Reinstall the bleed screw in the back of the eyelet with a 2mm hex and tighten clockwise to 14 in-lb (1.6 Nm). Unthread (counter-clockwise) and remove the DHX2 shaft eyelet from the shaft. Use a deep 14mm socket to unthread (counter-clockwise) the bearing assembly from the body. Remove the bearing assembly and inner body from the outer body by pulling up.

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Step 2

Add FOX 10wt. red oil to the main body. The oil will slowly transfer into the piggy-back reservoir through the eyelet. Stop adding oil once it has reached the level of the retaining ring groove on the inside of the reservoir.

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Step 3

Take a new nitrile glove and stretch it over the open main body making an airtight seal. 

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Step 4

Hold the glove tightly over the main body, then slowly push a finger into the main body and remove. This forces fluid and any air through the eyelet and adjuster, into the piggy-back reservoir. Repeat until you feel that only clean fluid is moving through the eyelet and no new bubbles appear in the reservoir.

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Step 5

Remove the glove and add fluid to the main body until the fluid level in the reservior slowly rises to the very top. 

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Step 6

Install a new greased o-ring onto the IFP, then slowly slide it into the reservoir making sure to not trap any air beneath it. Orient the IFP so the counterbore faces up. Keep the IFP flat and press it into the reservoir until it is beneath the retaining ring groove.

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img/help/page682-1NRT/IMG_0111.jpg
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img/help/page682-1NRT/IMG_0114.jpg
img/help/page682-1NRT/IMG_0115.jpg


img/help/page682-1NRT/IMG_0116-m.jpg

Step 7

Separate the inner body from the shaft assembly and slowly install it into the body with it's ports at the top. Push the inner body in to fully seat it in the eyelet.

img/help/page682-1NRT/IMG_0116.jpg
img/help/page682-1NRT/IMG_0117.jpg
img/help/page682-1NRT/IMG_0118.jpg


img/help/page682-1NRT/IMG_0119-m.jpg

Step 8

Top off the body and pre-fill all ports of the piston and bearing assembly with FOX 10wt. red oil. Quickly and smoothly, install the piston assembly into the body and turn it clockwise to begin threading it in.

img/help/page682-1NRT/IMG_0119.jpg
img/help/page682-1NRT/IMG_0122.jpg
img/help/page682-1NRT/IMG_0124.jpg
img/help/page682-1NRT/IMG_0127.jpg


img/help/page682-1NRT/IMG_0128-m.jpg

Step 9

Use a deep 14mm socket to tighten (clockwise) the bearing assembly to 145 in-lb (16.3 Nm). Reposition your shock in the vice so the bleed port on the back of the eyelet is the highest part of the shock as shown.

img/help/page682-1NRT/IMG_0128.jpg
img/help/page682-1NRT/IMG_0129.jpg


img/help/page682-1NRT/IMG_0131-m.jpg

Step 10

Remove the bleed screw from the back of the eyelet with a 2mm hex wrench. Set the IFP to the appropriate depth using your IFP depth setting tool (803-00-566). Reinstall the set screw with a new greased o-ring from the kit and tighten to 14 in-lb (1.6 Nm).

Shock Size IFP Height (+/-0.050in)
7.875 x 2.000 1.243in/ 31.57mm
7.875 x 2.250 1.243in/ 31.57mm
8.500 x 2.500 1.293in/ 32.84mm
8.750 x 2.750 1.343in/ 34.11mm
9.500 x 3.000 1.393in/ 35.38mm
10.500 x 3.500 1.443in/ 36.65mm
img/help/page682-1NRT/IMG_0131.jpg
img/help/page682-1NRT/IMG_0132.jpg
img/help/page682-1NRT/IMG_0133.jpg
img/help/page682-1NRT/IMG_0136.jpg


After completing the hand bleed, please return to step 29 for instructinos to finalize the shock rebuild.


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