07 32 mm R Cartridge Service

Disassembly

1. After removing the cartridge from the fork, place the cartridge body into shaft clamps and lightly tighten the vise.

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

   
    
2. Unthread the rebound knob screw with a .050" Allen hex key. Put the rebound knob aside.
   
   
3. Remove the damper shaft and top cap assembly from the cartridge body by unthreading the seal head with a 13mm open end wrench.
   
   
4. The above photo shows a closeup view of the rebound damper piston, glide ring, seal head and damper shaft. Set this assembly aside for now.
   
   
5. Remove the cartridge body from shaft clamps and pour the oil into a drain pan.
   
    
6. Place the cartridge body back into the shaft clamps and using your 21mm open end wrench, remove the base valve from the cartridge body coupler.

   CAUTION:  Do over tighten, or damage will result to cartridge body coupler!

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

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

   
   
8. The above photo shows the cartridge body and base valve coupler after removing the base valve. Set this assembly aside for now.
   
   
9. Place base valve back into shaft clamps, and unthread the base valve piston bolt with a 13mm open end wrench.
   
   
10. Remove the base valve bolt and shims all together. Be very careful to keep all the shims in order.
    
    
11. The above photo shows all the base valve piston parts laid out in assembly sequence order.
    
    
12. Place the damper shaft into your shaft clamps and remove the glide ring from the piston; replace as needed.
    
    
13. Unthread the piston bolt with an 8mm open end wrench.
    
    
14. Remove the piston assembly from the damper shaft. Keep all the valve shims in order.
    
    
15. Remove the rebound piston check shim, spring, and little spring washer from the damper shaft.

    Note:  The small end of the spring faces the spring washer.

    
    
16. Remove the wire ring from the damper shaft.
    
    
17. The above photo shows all the rebound piston parts in assembly sequence order. This is a good time to inspect the parts, and clean them if necessary.
    
    
18. Remove the damper shaft from the shaft clamps.
    
    
19. Grease the end of the shaft and slide the seal head off the damper shaft. Set the damper shaft aside.
    
    
20. Remove the o-ring from the seal head.

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

    
    

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

Assembly

1. Apply grease to the seal head o-ring.
   
   
2. Install the o-ring into the seal head.
   
   
3. Apply grease to the damper rod.
   
   
4. Install the seal head onto the damper rod.
   
   
5. Install the wire ring onto the damper rod.
   
   
6. Install the rebound check shim assembly.

   Note:  Install the small end of spring onto damper rod end 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 piston bolt.
   
   
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 the glide ring onto rebound piston.
    
    
11. Carefully set the damper shaft into the shaft clamps in the vise, and torque the piston bolt to 25 in/lb with an 8mm socket wrench.
    
    
12. Inspect the check shim for normal free play, i.e., so it will open freely.
    
    
13. Assemble the base valve piston bolt with shims.
    
     
14. Apply a drop of blue Locktite to the threads of the piston bolt. Next, thread the piston bolt into the base valve.
    
     
15. Insert the small end of the cone spring into the coupler, followed by the check valve spring.
    
     
16. Apply a single drop of blue Locktite to the bottom OD threads of the base valve. Next, thread the base valve assembly into the coupler.
    
     
17. Carefully set the cartridge assembly into the shaft clamps and lightly tighten the vise.

    CAUTION:  Do not over-tighten or you'll risk damaging the cartridge body. Torque the piston bolt into the coupler to 45 in/lb. with a 21 mm crows foot wrench.

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

    CAUTION:  Do not over-tighten the vise, or damage to the cartridge body will result.

    
    
20. Apply a drop of blue Locktite to the seal head OD threads.
    
     
21. Gently thread the seal head into the cartridge body.
    
    
22. Use the 13mm crows foot wrench with 45 in/lb to tighten.
    
     
23. Insert the top cap into the rebound knob. Tighten screw with .050" hex key wrench.

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FOX Factory Inc.