2007 32mm RL and RLC Cartridge Service

Disassembly

1. With the RL or RLC FOX FORX, remove the red rebound knob by holding it firmly and loosening its screw with a 2mm hex key. Do not allow the knob to rotate when loosening the screw. If the knob reaches either end of its rotation and pressure is applied, internal parts will break. If you are unable to securely hold the knob with your fingers, use needle nose pliers with protective tips (wrap with tape). Place needle nose pliers against opposing raised surfaces of the knob and loosen the screw.

   Note:  The RL and RLC procedures are the same,except the RL does not have the low-speed compression dial shown in the pictures below.

   
   
2. Remove the rebound knob by lifting it off the end of the rebound adjuster rod.
   
   
3. Loosen the three set screws in the top of the blue lockout lever about 1 1/2 full turns.
   
   
4. Lift the lockout lever straight up to remove. Be careful not to drop and lose the three small steel balls on the inside diameter of the lever. The three steel balls are held in place by a dab of grease. They must remain on the inside diameter of the lockout lever, as shown in the right side photo below.
   
      
5. After removing the cartridge from the fork, place the cartridge body into shaft clamps and lightly tighten the vise.

   CAUTION:  Do over tighten with the vise, or damage will result to the cartridge body!
   
   

   
   
6. Remove the damper shaft assembly from the cartridge body by unthreading the seal head with a 13mm open end wrench.
   
   
7. This photo shows an up-close view of the rebound damper piston, glide ring, seal head and damper shaft. Set this assembly aside for now.
   
   
8. Remove the cartridge body from the shaft clamps and pour any remaining oil into your oil drain pan.
   
    
9. Place the cartridge body coupler (the silver part) back into shaft clamps. Using your 21mm open end wrench, remove the base valve from the cartridge body coupler.

   CAUTION:  Do over-tighten with the vise, or damage will result to the body coupler!
   
   

   
   
10. Remove the base valve check shim and check spring from the coupler.

    Note:  The spring has a conical shape; the smaller OD will always face up towards the check shim.

    
    
11. This photo shows the cartridge body and base valve coupler after removing the base valve. Set this assembly aside for now.
    
    
12. Replace the base valve back into the shaft clamps, and unthread the base valve piston bolt with a 13mm open end wrench.
    
    
13. Remove the base valve bolt and shims all together, being very careful to keep all the shims in assembly order.
    
    
14. This photo shows all the base valve piston parts after being cleaned, and in assembly order.
    
    
15. Place the damper shaft into your shaft clamps and remove the glide ring from the piston; replace if necessary.

    CAUTION:  Do over tighten with the vise, or damage will result to the damper shaft!
    
    

    
    
16. Unthread the piston bolt with an 8mm open end wrench.
    
    
17. Remove the piston assembly from the damper shaft. Keep all the valve shims in assembly order. It's best to keep the piston bolt and damper piston assembly together.
    
    
18. Remove the rebound piston check shim, spring, and the little back up washer from the damper shaft.

    Note:  Be sure the small end of the spring faces the small OD back up washer.

    
    
19. Remove the wire ring from the damper shaft.
    
    
20. The above photo shows all the rebound piston parts in order of assembly. Take this time to inspect and clean all the parts.
    
    
21. Remove the damper shaft from the shaft clamps.
    
    
22. Put a little dab of grease on the end of the damper shaft, and slide the seal head off the damper shaft. Set the damper shaft aside.
    
    
23. Remove the o-ring from the seal head gland.

    Note:  This photo shows a yellow plastic o-ring pick. Always be careful not to damage the seal glands when removing seals or the o-rings from them. A scratch in the gland will result in seal leakage.

    
    
24. The above photo shows the o-ring removed from seal head gland.

Assembly

1. Apply grease to the new seal head o-ring.
   
   
   
2. Install the o-ring into the seal head.
   
   
3. Apply grease to the end of the damper rod.
   
   
4. Install the seal head onto the damper rod. Be very careful as you push seal head onto the shaft; you do not want to nick or cut the o-ring during its installation.
   
   
5. Install the wire ring onto the damper rod.
   
   
6. Install the rebound check shim assembly.

   Note:  Position the small end of spring onto the damper rod first.

   
   
7. Assemble the rebound piston assembly with the piston bolt.
   
   
8. Apply a single drop of blue Locktite onto the last couple of threads of the piston bolt.

   CAUTION:  Do not over-do the Locktite, as it will flow out onto the check shim and cause it to stick.

   
   
9. Install the rebound piston assembly onto the damper rod. Thread the bolt in by hand, making sure not to crimp or damage the check shim.
   
   
10. Install piston glide ring and place the damper shaft into the shaft clamps in the vise. Torque the piston bolt to 25 in/lb with an 8mm socket wrench.

    CAUTION:  Do not over tighten the shaft clamps in the vise!
    
    

    
    
11. Inspect the check shim for normal free play (i.e., it opens).
    
    
12. Assemble the base valve piston bolt with the shims, as shown above.
    
     
13. Apply a single drop of blue Locktite to the threads of the piston bolt. Next, thread the piston bolt into the base valve.
    
     
14. Insert the small end of the conical spring into the coupler, followed by the check valve shim.
    
     
15. Apply a single drop of blue Locktite to the bottom OD threads of the base valve. Thread the base valve assembly into the cartridge body coupler.
    
     
16. Set the cartridge body into the shaft clamps and lightly tighten the vise.

    CAUTION:  Do not over-tighten the vise, or you'll risk causing damage to the cartridge body.

    Torque the piston bolt into the coupler to 45 in/lb. with a 21mm crows foot wrench.

    
    
17. Double-check the snugness of the base valve piston bolt with the 13mm crows foot wrench. Torque to 45 in/lb.
    
    
18. Remove the cartridge body assembly from the shaft clamps, invert and replace it into the shaft clamps in the vise, as shown.

    CAUTION:  Do not over-tighten the vise, or you'll risk damage to the cartridge body.

    
    
19. Apply a single drop of blue Locktite to the seal head OD threads.
    
     
20. Gently thread the seal head into the cartridge body.
    
    
21. Use the 13mm crows foot wrench an torque seal head to 45 in/lb.

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FOX Factory Inc.