2014-2015 40 FLOAT Bath Oil and Dust Wiper Service
WARNING: Always wear safety glasses and protective gloves during service to prevent potential injury. Failure to wear protective equipment during service may lead to SERIOUS INJURY OR DEATH.
WARNING: FOX products should be serviced by a qualified 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.
Remove the blue air cap and release the air pressure. Be careful as some Float Fluid might spray from the air valve.
With the fork slightly inverted (the bottom of the fork up past horizontal), remove the black cover, then use a 2mm hex wrench to remove the red rebound knob.
With the fork slightly inverted (the bottom of the fork up past horizontal) remove the bottom nuts with 10mm and 15mm sockets. Remove the crush washers.
Use Damper Removal Tools 398-00-430 and 398-00-601 to dislodge the shafts from the lowers. Make sure that you have approximately half of the available threads engaged with your tool before striking with your mallet. Bring fork upright over an oil basin to drain.
Remove the lower leg assembly and set it aside. Remove the Retaining Ring (038-00-024) followed by the Negative Spring Plate.
Insert the 40 FLOAT Air Piston Seal Bullet Tool (398-00-579) into the bottom end of the air side upper tube. Use a shock pump to add a small amount of air to the air chamber to help slowly push the Air Shaft Assembly out far enough to grip. Gently pull the Air Shaft Assembly out the rest of the way. Remove the bullet tool.
With a chamfer-less 6-point 32mm socket, unthread the topcap assembly completely. Pull straight up to remove the entire topcap assembly from the left side stanchion tube.
Replacing the Dust Wipers
Using a wooden or plastic dowel is the recommended method for removing the dust wipers and foam rings. If you choose to use a wrench or other metallic tool, use extra caution not to scratch the inner wall of the magnesium lower leg, as you lever out the dust wiper. Do this by making sure the tip of your metallic tool is cushioned from the magnesium lower leg by the foam ring, just below the dust wiper.
Thoroughly clean the seal bore and the inside of the lower legs with warm soapy water or Isopropyl alcohol. Blow the lowers dry with clean compressed air. Install a new foam ring soaked in FOX 20wt. Gold Oil.
Use a small amount of FOX 20wt. Gold oil to coat the outside of the new dust wiper beneath the flange. Set the wiper in place above the soaked foam ring. Use the 40mm Fox Lower Leg Seal Driver Tool (PN: 398-00-513) to press the new wiper into the seal bore. Hold the Seal Driver Tool hard against the installed seal keeping downward pressure on the seal for 10-15 seconds to make sure the seal is installed completely.
Coat the inside of the seal with a thin film of FOX 20wt. Gold oil. Repeat these steps to replace both dust wipers.
After cleaning the inside of the Air Side upper tube with Isopropyl alcohol, install the 40 FLOAT Air Piston Seal Bullet Tool (398-00-579) into the bottom end of the air side upper tube.
Replace the air and oil seals on the main piston and coat the Air Piston Assembly with FOX Float Fluid and then carefully install the Air Shaft Assembly into the upper tube through the bullet tool. Remove the bullet tool.
Gently pull on the Air Shaft Assembly to guide the shuttle through the Negative Spring Plate. Invert the fork and pour in 10cc of FOX Float Fluid.
Coat the Compression Bulkhead and the top 2 inches (~50mm) of the inside of the upper tube with Float Fluid then carefully install the Topcap Assembly into the upper tube. Torque to 220in-lb (24.8 Nm).
Pour 50cc of FOX 20wt. Gold oil into each leg through the bottom hole. Install a new crushwasher on each side followed by the appropriate bottom nut. Torque both bottom nuts to 50in-lb (5.7 Nm).
Use a 2mm hex wrench to install the red rebound knob. Make sure that the set screw lines up with the depression in the rebound adjuster shaft. Install the black rebound knob cover. Add 65psi of air pressure to your fork and replace the blue air cap. Clean the exterior of your fork.