Fox32 Mountain Bike Front Air Suspension Fork Seal and Oil Replacement

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

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.

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

Remove the front brake caliper.

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

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

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

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.

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

Remove the wheel from the fork.

Set aside for safe keeping.

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

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.

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

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

Remove the stem cap by turning the bolt counter clockwise.

Slide the stem off the steer tube.

Begin to slide the steer tube out of the frame.

Remove the upper portion of the headset.

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

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

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

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

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.

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

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

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.

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.

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.

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

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

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

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

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

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

Soak the white bushings in fork oil.

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

This is now how the dust seals should look.

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

Use brake clean or another degreaser to clean the stanchions.

Insert the fork stanchions into the fork body part way.

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

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

Pipe the fluid into the bottom of the fork body.

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

Thread the nut onto each nipple by hand.

Use a socket to tighten each nut.

Reinstall the rebound knob.

Turn the Allen bolt clockwise to secure the knob.

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

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

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

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

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

Regrease the head set component removed earlier.

Reinsert the headset component back into the frame.

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

Insert the fork back into the frame.

Grease the spacer that goes onto the steer tube.

Reinsert the stem spacer onto the steer tube.