Step 1

Clamp your shock 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.

Step 2

Thread a cloth rag through the body eyelet of your shock, then unthread the air sleeve by turning it counter-clockwise. Unthread the rag and pull the air sleeve off to remove. 

Step 3

Replace the seals in the end of the air sleeve with new greased ones from the rebuild kit as shown. Set aside in a clean area once complete.

Step 4

Turn the blue compression adjust lever and the red rebound knob to the open position (fully counter-clockwise).

Step 5

Using a Torx T8, unthread the air fill cap counter-clockwise to access the air valve. Release the IFP pressure by depressing the valve stem inside the body.

Step 6

Use a 2mm hex wrench to slowly remove the bleed screw by turning it counter-clockwise. Use a magnet to remove the ball from under the bleed screw. Unthread the bearing assembly from the shock body with a 32mm wrench.

Step 7

Remove the shaft assembly from the body and pour out the damper oil. Remove the IFP by threading the air fill adaptor (PN: 803-01-985) clockwise into the body. Carefully apply air pressure with your pump to remove the IFP. Inspect the body for damage or excessive wear. Remove your shock pump, leaving the air fill adaptor threaded into the shock body.

Step 8

Remove the IFP o-ring and inspect its gland on the piston itself for any damage or contamination. Apply Slick Honey grease to the new IFP o-ring from the replacement seal kit, and install it on the piston.

Step 9

Apply a very thin film of Slick Honey to the inside of the shock body, then insert the IFP with it's slot facing up. Adjust your calipers to the correct IFP depth for your shock. Use your caliper to push the IFP down to it's appropriate depth. Remove the air fill adaptor.

Step 10

Clamp the eyelet assembly in your soft-jawed vice and carefully lift up on the lockout plate to remove.

Step 11

Use the FLOAT lockout piston tool (PN: 398-00-949) to unthread the lockout piston by turning it counter-clockwise.

Step 12

Remove the lockout piston then remove the lockout shim stack with a magnet.

Step 13

Use the FLOAT piston bolt tool (PN: 398-00-950) to unthread the piston bolt counter-clockwise. Remove the piston assembly and set it aside.

Step 14

Remove the bearing housing assembly followed by the bottom out bumper, bottom out plate and volume spacer if present.

Step 15

Clean the shaft with Isopropyl alcohol and a lint-free paper towel. Carefully clamp the shaft in your shaft clamps (PN: 803-00-805). Heat the area of the eyelet at the shaft to break down the Loctite. Be careful as the eyelet and shaft can be hot after using your torch to break down the Loctite.

Step 16

Unthread the eyelet counter-clockwise, then lift up to remove (for trunion eyelets use eyelet torque fixture 398-00-951. For standard eyelets use eyelet torque tool 398-00-280).

Step 17

Remove the rebound metering rod by pulling it up and out of the shaft. Be careful not to lose the small ball bearings at the end of the rebound metering rod. Carefully remove any Loctite residue from the shaft and eyelet with a plastic pick tool.

Step 18

Carefully remove the o-ring from inside the shaft and rebound metering rod with a pick tool. 

Step 1

Use a 1.5 mm hex wrench to remove the set screw from the top of the eyelet assembly. Remove the Float lever assembly by pulling it out of the eyelet. Be careful not to lose the detent ball from behind the lever assembly. Remove the detent bearing and spring with a magnet. Clean the bare eyelet and set aside.

Step 2

Use a 1.5mm hex wrench to unthread the rebound knob set screw counter-clockwise. Remove the red rebound knob by pulling it away from the lever assembly. Remove the cam by pulling it out of the lever assembly from the back. Use 1.5mm hex wrench to remove the rebound set screw from eyelet by turning it counter-clockwise. Be carefull not to lose the detent ball and spring. Remove the rebound gear from the inside of the eyelet using a magnet. Use a thin shim to remove the small retaining ring that holds the black adjuster to the blue compression selector lever.

Step 3

Insert the black adjuster into the blue compression selector lever followed by the spring, spring retainer, and retaining ring. Compress the spring against the blue compression selector lever to make room to install the retaining ring. Reinstall the red rebound knob and tighten the 1.5mm set screw clockwise to 5 in-lb (0.6 Nm) torque. Coat the cam and spring with a film of waterproof grease such as Sta-Lube SL3125 or Ultraplex LT2.

Step 4

Insert the rebound gear into the eyelet then insert the greased detent spring into the small hole in the face of the eyelet, followed by the detent ball. Carefully insert the lever assembly into the eyelet without dislodging the detent ball and spring. Compress the detent spring by pushing the lever assembly into the eyelet, then install and gently tighten the set screw in the top of the eyelet fully, then back it out 1/4 turn.  Insert the rebound detent ball and spring on the side of the eyelet, then install and gently tighten the set screw.

Step 1

Install new greased seals from the kit into the shaft and metering rod.

Step 2

Coat the narrow end of the rebound metering rod with a thin film of Slick Honey and carefully insert it into the internal shaft o-ring to seat it completely within its groove.

Step 3

Replace the two o-rings within the eyelet with new greased ones from the kit. 

Step 4

Apply a small drop of red Loctite 277 to the shaft threads. Install the shaft into the eyelet with the ball bearing on the metering rod oriented toward the rebound cam.

Step 5

Clean the shaft with Isopropyl alcohol then clamp it in your shaft clamps. Use your eyelet torque tool (PN: 398-00-280 or 398-00-951 for trunion eyelets ) to tighten the eyelet to 85 in-lb (9.6 Nm) torque.

Step 6

Reinstall any volume spacers if present followed by the bottom out plate followed by a new bottom out bumper from the kit. Reinstall the bearing housing cap making sure to orient the counter-bores on the cap towards the eyelet.

Step 7

Replace the two o-rings within the bearing assembly with new greased ones from the kit. Coat the shaft with a thin film of Slick Honey, then reinstall the bearing assembly onto the shaft.

Step 8

Install the valving assembly with piston bolt. Tighten the piston bolt clockwise with the FLOAT piston bolt tool (398-00-950) to 60 in-lb (6.8 Nm).

Step 9

Reinstall the lockout shim stack, followed by the lockout piston. Tighten the lockout piston clockwise to 22 in-lb (2.5 Nm) with the FLOAT lockout piston tool (PN: 398-00-949).

Step 10

Insert the compression rod through the lockout piston, being careful not to damage the o-ring within the rebound metering rod or bending the compression rod. Align the hole in the Tri-lobe plate with the pin in the lockout piston.

Step 11

Turn the red rebound knob and blue compression selector lever to their open positions (fully counter-clockwise).

Fill the body with FOX 4wt. oil. Slide the bearing assembly toward the piston assembly, then pre-fill the piston assembly with FOX 4 wt. Suspension Fluid. Invert the shaft assembly inserting the piston assembly into the previousely prepared and filled shock body. Thread the bearing assembly clockwise onto the body then tighten to 240 in-lb (27.1 Nm) with your 32mm wrench. 

Step 12

Insert the ball bearing followed by the bleed screw into the bleed hole in the bearing assembly. Tighten the bleed screw clockwise to 10-15 in-lb (1.1-1.7 Nm) with a 2mm hex wrench. 

Step 13

Install the air fill adaptor by threading it in clockwise. Set the IFP pressure to 550 psi. Remove the air fill adaptor while still attached to your high pressure pump. Reinstall the air fill cap with a new greased o-ring from the kit, tightening clockwise to 3 in-lb (0.3 Nm) torque.   

Step 14

Coat the main air seal and backup rings on the bearing assembly with a thin film of FOX 20wt. gold oil. Coat the seals and backup rings in the end of the air sleeve with a thin film of FOX 20wt. gold oil. Begin to reinstall the air sleeve assembly onto the shock damper. Add 2cc of FOX 20wt. gold oil into the positive air chamber. Push the air sleeve assembly to the eyelet then tighten clockwise until hand tight. Add air to your desired pressure then reinstall the black air cap. Clean the exterior of the shock then dyno test all functions.