luthj
Engineer In Residence
Greetings,
Many van owners have discovered the improved ride offered by the Fox 2.0 series shocks over many OEM and aftermarket options. I had a hard time finding a good photo essay of a 2.0 rebuild, so here goes.
Recently one of my rears blew a seal. Its been seeping slightly for about 18 months. Its had about 80k miles of abuse over multiple continents, so it doesn't owe me anything! Now I have adjustable external reservoir units, so they are a bit pricey. I decided to do a rebuild myself, and many of the steps will apply to emulsion and non-adjustable units.
The guide I am using is attached.
Here is the unit in-situ. Once the seal blew, it leaked until the IFP bottomed out, so about 200ml of shock oil.
IMG_20190420_104539448_HDR by J Luth, on Flickr
The first step is to thoroughly clean the exterior of the shock. Use a pick to remove crud from the reservoir end caps, and the groove around the bearing end cap ( black thing around the shaft).
IMG_20190423_131626312_HDR by J Luth, on Flickr
Here is the kit I am using. It was about 15$. There are a couple versions depending on the shock model.
IMG_20190423_131632327_HDR by J Luth, on Flickr
Next we release the gas charge. This screw has a small hole down the middle. Loosen it about 1 turn, then use an inflation needle to release the gas. I found this a bit tricky, so I gradually loosened it until it started leaking, then used the needle to get the last bit. Don't remove it completely, otherwise the screw and valve will rocket across the room (and get lost!)
IMG_20190423_132622105_HDR by J Luth, on Flickr
Next separate the cap/wiper seal from the body. There is a special tool for this, but some rubber pliers and a mallet (rubber vise jaws etc) works. My shocks are already banged up, so I just used a screwdriver with gently tapping.
IMG_20190423_133123806_HDR by J Luth, on Flickr
There will be some crud under it. Clean as best you can.
IMG_20190423_133149715_HDR by J Luth, on Flickr
To remove the bearing/seal carrier, you need to press it inwards about 1/4". If you have pressure in the shock it may rebound. I used a rubber mallet and a wooden down to free it up. Once pressed down you can see the snap ring. Pry it out with a pick, don't scratch the sealing surface farther down!
IMG_20190423_133152569 by J Luth, on Flickr
IMG_20190423_133218300 by J Luth, on Flickr
IMG_20190423_133834597_HDR by J Luth, on Flickr
With the snap ring removed, and any debris cleaned out, pull the bearing/shaft from the body. Spray some lube into the bore to make the O-ring slide over the groove easier. Put the shock in a vise (or between your legs) and pull/yank while rocking back/forth a bit. Avoid hitting the shaft with anything, you may damage the bearing. There will be a lot of oil, so be prepared for it to gush out when it finally comes free.
Many van owners have discovered the improved ride offered by the Fox 2.0 series shocks over many OEM and aftermarket options. I had a hard time finding a good photo essay of a 2.0 rebuild, so here goes.
Recently one of my rears blew a seal. Its been seeping slightly for about 18 months. Its had about 80k miles of abuse over multiple continents, so it doesn't owe me anything! Now I have adjustable external reservoir units, so they are a bit pricey. I decided to do a rebuild myself, and many of the steps will apply to emulsion and non-adjustable units.
The guide I am using is attached.
Here is the unit in-situ. Once the seal blew, it leaked until the IFP bottomed out, so about 200ml of shock oil.
IMG_20190420_104539448_HDR by J Luth, on Flickr
The first step is to thoroughly clean the exterior of the shock. Use a pick to remove crud from the reservoir end caps, and the groove around the bearing end cap ( black thing around the shaft).
IMG_20190423_131626312_HDR by J Luth, on Flickr
Here is the kit I am using. It was about 15$. There are a couple versions depending on the shock model.
IMG_20190423_131632327_HDR by J Luth, on Flickr
Next we release the gas charge. This screw has a small hole down the middle. Loosen it about 1 turn, then use an inflation needle to release the gas. I found this a bit tricky, so I gradually loosened it until it started leaking, then used the needle to get the last bit. Don't remove it completely, otherwise the screw and valve will rocket across the room (and get lost!)
IMG_20190423_132622105_HDR by J Luth, on Flickr
Next separate the cap/wiper seal from the body. There is a special tool for this, but some rubber pliers and a mallet (rubber vise jaws etc) works. My shocks are already banged up, so I just used a screwdriver with gently tapping.
IMG_20190423_133123806_HDR by J Luth, on Flickr
There will be some crud under it. Clean as best you can.
IMG_20190423_133149715_HDR by J Luth, on Flickr
To remove the bearing/seal carrier, you need to press it inwards about 1/4". If you have pressure in the shock it may rebound. I used a rubber mallet and a wooden down to free it up. Once pressed down you can see the snap ring. Pry it out with a pick, don't scratch the sealing surface farther down!
IMG_20190423_133152569 by J Luth, on Flickr
IMG_20190423_133218300 by J Luth, on Flickr
IMG_20190423_133834597_HDR by J Luth, on Flickr
With the snap ring removed, and any debris cleaned out, pull the bearing/shaft from the body. Spray some lube into the bore to make the O-ring slide over the groove easier. Put the shock in a vise (or between your legs) and pull/yank while rocking back/forth a bit. Avoid hitting the shaft with anything, you may damage the bearing. There will be a lot of oil, so be prepared for it to gush out when it finally comes free.