F-O-A Shock Rebuild Instructions

(Leave shock pressurized to begin, as it will assist with removing wipercap)

1. Clean shock, and put into soft jawed vice or something to hold it upside-down.
2. Loosen wiper cap with a spanner wrench/channel-lock pliers. Unscrew and slide wiper cap assembly up shock shaft.
3. De-pressurize shock completely.
4. Push sealhead assembly downward into shock to expose snap ring. Remove snap ring.
5. Remove shaft / sealhead assembly by rocking back and forth and pulling out at the same time, set aside.  (Watch for the wear band that will come off the piston as the assembly pulls out of shock body)
6. Depress reservoir end cap. (Schrader end). Remove snap ring and reservoir end cap. ( If end cap is difficult to remove, you may need to add some air pressure to help “pop” it out. Be VERY careful if you decide to do so, as it can fly out with force.) If you’de rather not add pressure, follow next step and then push schrader end out from the backside once the reservoir is disassembled.
7. Dump all old oil from shock/reservoir. Depress reservoir end cap. (Hose end). Remove snap ring, remove hose and end cap from reservoir. Remove IFP (Internal Floating Piston) from inside reservoir.
8. Clamp shaft assembly in a vise, using the eyelet. Remove valving, sealhead assembly, and wiper cap assembly. Make sure to keep all valve shims and piston in the same order as removed.
9. With a scribe remove all seals from bearing cap, bearing assembly, reservoir end caps, and IFP. Clean all parts. (Be careful not to damage any sealing surfaces)
10. Inspect all valve plates and damping piston, look for cracks or any signs of fatigue.
11. Check shaft to see that it is not bent or has any deep pits. Replace if required.
12. Install new seals on all parts. Use a small amount of grease on sealhead assembly and cap.
13. Install wipercap and sealhead  assemblies onto shaft. Be careful not to damage any seals.
14. Install valving assembly, piston and lock-nut. Torque nut to 30 ft./lb.
15. Clean body assembly, place in a vise open end up.
16. Clean reservoir body. Lube re-sealed IFP, install flush with the end of the reservoir body. (Schrader valve end)
17. Fill reservoir with 5 wt. oil. Reconnect reservoir assembly to hose assembly. Install snap-ring, check to be sure it is seated completely.
18. On the remote reservoir, push the IFP in 8” from the open end of the reservoir. On the piggyback reservoir, push the IFP in 6” from the open end of the reservoir. This will force any en-trapped air into the shock body.
19. Fill the body with oil, leaving a 2” air gap at the top.
20. Insert shaft and valving assembly into shock. Gently move the shaft assembly in and out until all the air bubbles are removed. You are trying to bleed any air that may be trapped in the shock.
21. Check the IFP location, it may have moved. Reset if needed.
22. Top off the shock with oil to about 1/4” from the top.
23. Slowly insert the sealhead assembly into the shock body. Oil will typically spill out of shock as sealhead goes in. Push the sealhead in so that the snap ring can be installed.
24. Install the snap ring. Check to be sure it is completely in its groove. This is very important!
25. Install wiper cap assembly. Screw it onto the sealhead assembly until it is snug.
26. Lube and install the reservoir end cap. Install the last snap ring.
27. Compress the shaft all of the way into the shock. This should set the reservoir end cap into position. (It should make a pop / snap sound).
28. Pressurize the reservoir with 120-180 psi. Install reservoir schrader valve cap.
29. Tighten down wipercap cap assembly.
30. Remove the shock from the vise. Compress the shock to make sure it is working properly.