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Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement

Introduction

This guide will walk you through the steps of replacing seals on a Fox mountain bike fork (often called an "uppers service"). These steps can be applied to any modern Fox fork, though this guide focusses on a 2012 Fox 32 factory fork. Be sure to check the Fox website for the correct parts, fluid, and fluid volumes to use no matter what fork you are using (this will be done using the serial number on the fork).

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  1. Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement, Fork Seal and Oil: étape 1, image 1 de 1

    • Begin by finding a flat location to lay your bike down.

    • Be prepared for your bike to stay in this location until the fork has been serviced (potentially several hours).

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    • Begin to remove the front brake caliper. Find the appropriate sized Allen key from your set, and remove the bolt by turning it counter clockwise.

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    • Remove the second front brake caliper bolt by unscrewing it counter clockwise.

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    • Remove the front brake caliper.

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    • Insert the caliper pad spacer to ensure the pistons cannot move while the caliper is off the fork.

    • You can alternatively use a wooden shim to keep the brake pads separated.

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    • Reinstall the brake caliper bolts into the fork for safe keeping. Insert and turn clockwise.

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    • Use a zip tie to secure the brake caliper to the handle bars.

    • This step will ensure the brake caliper does not move around excessively and stress the brake line.

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    • Find the correct Allen key to remove the brake line bracket from the fork.

    • Remove by turning the bolt counter clockwise.

    • After the brake line is removed from the bracket, screw the bracket back onto the fork.

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    • Remove the thru-axle by flipping the lever down and unscrewing counter clockwise.

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    • Remove the wheel from the fork.

    • Set aside for safe keeping.

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    • Reinsert the thru-axle into the fork for safe keeping.

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    • Find the proper sized Allen key to loosen the stem clamp bolts.

    • Loosen each stem bolt at least 3 turns by turning counter clock wise.

    • Do not remove the bolts entirely.

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    • Loosen the second stem bolt by turning counter clockwise at least 3 turns

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    • Find the appropriate sized Allen key to fit the stem bolt.

    • Remove the stem cap by turning the bolt counter clockwise.

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    • Slide the stem off the steer tube.

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    • Begin to slide the steer tube out of the frame.

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    • Remove the upper portion of the headset.

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    • Zip tie the headset components to the frame for safe keeping.

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  19. Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement: étape 19, image 1 de 1

    • This is all the disassembly that should have been done. Keep everything organized for easy assembly!

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    • Screw the top cap back into the steer tube on the fork for safe keeping.

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    • Remove the cap on the left side of the fork by turning counter clockwise, exposing an air valve.

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    • Use a small allen key (2.5mm was used in this case) to release all of the air from the fork.

    • Notice how the fork compresses when all the air has been released.

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    • On a work surface, flip the fork upside down and locate the red rebound knob.

    • Locate the small allen bolt and find the appropriate sized allen key. Loosen the bolt by turning counter clockwise 3 rotations and remove the rebound knob.

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    • Find the appropriate sized hex socket to fit the nut that is under the rebound knob. Remove by turning counter clockwise.

    • Note: Keep in mind a long socket handle may make removal easier.

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    • Remove the nut on the bottom of the other stanchion using the same process.

    • The nut size should be the same.

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    • Find a small socket that will rest on the shoulder below the threads but not damage the threads on the rebound side of the fork.

    • Use a soft headed mallet to lightly tap on the socket.

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    • Screw the nut part way onto the threads on the other side.

    • Use a soft headed mallet and lightly tap on the nut.

    • Remove the nut and socket from the threaded parts of the fork.

    • Keep the fork inverted for the entirety of this step.

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    • Get a large container to capture the oil inside the fork.

    • Flip the fork over above the large container, keeping in mind that oil will begin to flow out once the fork is turned right side up.

    • Hold the fork above this container and slide the stanchions out of the fork body.

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  30. Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement: étape 29, image 1 de 1

    • The stanchions should now be separated from the fork.

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    • Use a flat wrench to pry the dust seals out of the fork body.

    • Be very careful to not scratch the inside of the fork body with the wrench.

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  32. Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement: étape 31, image 1 de 1

    • Perform this step on the other side of the fork body.

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    • Use a rag to clean the surface that the dust seal sits on.

    • There is likely lots of dust on and around this surface, so wipe it down well.

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    • Rest the new dust seal over where the old one was removed.

    • The metal ring should be facing down.

    • Use a socket the same diameter of the dust seal and a mallet to seat the dust seals.

    • Be very gentle and do not damage the dust seals. It may take several small taps.

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  35. Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement: étape 34, image 1 de 1

    • Both dust seals should now be seated in the fork body.

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    • Soak the white bushings in fork oil.

    • Pour enough oil to cover the bushings

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    • After letting the bushings soak for ~5 minutes, insert them into the dust wipers.

    • They should easily seat in place. The oil will help keep a seal and provide lubrication.

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    • This is now how the dust seals should look.

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    • Apply a small drop of grease to the inside of each dust seal.

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    • Use brake clean or another degreaser to clean the stanchions.

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    • Be sure the rods in the bottom of the stanchions are fully extended.

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    • Insert the fork stanchions into the fork body part way.

    • Do not fully insert.

    Modifier

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    • Using the serial number on your fork, determine from the manufacturer website how much oil should be added to each side of the fork.

    • In this case, it was 30 mL total.

    • Dump the measured quantity of oil into a plastic bag. Close the bag, invert, and cut a small part of a corner off.

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    • Pipe the fluid into the bottom of the fork body.

    • This fork used an equal amount of oil for each side. If the manufacturer recommends a different amount of oil for each side, it may be wise to measure and pipe oil into each side separately.

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    • Compress the fork enough for the threaded nipples to come through the bottom of the fork.

    • Keep the fork inverted for the remainder of the assembly.

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    • Thread the nut onto each nipple by hand.

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    • Use a socket to tighten each nut.

    • They should be tight, but do not need to be cranked down.

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    • Reinstall the rebound knob.

    • Turn the Allen bolt clockwise to secure the knob.

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    • At this point, the fork can be turned right side up.

    • Unscrew the cap covering the air input (opposite side from the damper).

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    • Use a shock pump to air the fork to the desired pressure.

    • As a rule of thumb, this should be about 50% of rider weight in PSI. Consult the manufacturer website or manual for a more precise value.

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    • Clean the inside of the head tube using a clean rag.

    • Be sure to remove as much old grease as possible.

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    • Apply a drop of grease to the inside of the head tube.

    Modifier

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    • Regrease the head set component removed earlier.

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    • Reinsert the headset component back into the frame.

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    • Grease the headset component in the bottom of the head tube, and the base of the steer tube.

    Modifier

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    • Insert the fork back into the frame.

    • Be careful when reinstalling so that no parts of the headset assembly are knocked off during reassembly.

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    • Grease the spacer that goes onto the steer tube.

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    • Reinsert the stem spacer onto the steer tube.

    • From here on, assembly is the reverse of disassembly.

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    • When reinstalling the handlebars, ensure they are aligned with the front wheel. This is best done by standing over the bike and looking down on the handlebars and wheels.

    Modifier
Conclusion

To reassemble your device, follow these instructions in reverse order.

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