r/bikewrench • u/l008com • 1h ago
Weird Situation with a Fox 36 Service.
So I rebuild the fork on my bike periodically. Not as often as I should, but I've done it a bunch of times.
So a few weeks ago, I was way overdue, so I did a full service. Well not internal O rings but new seals no fluids etc. Cleaned it all out etc.
The lowers were all clean, new foamies installed, new seals. Foam was soaked in new oil, seals were freshly greased up. But when I went to put them on, they seemed to bind up. In a way I've never experienced before. I had to push really hard to get them on. Then I finished the reassembly and put the fork back on. It was working, but it was kind of sticky. It wasn't super plush like they usually are after a rebuild.
At this point, I figured one of the foam rings must have gotten pinched and caught between the stanchions and the bushings in the lowers.
Over time it loosened up a little bit but last night I took it apart again to fix it.
This is where things got very strange. There were some small pieces of chewed up foam rings that came out with the oil. BUT when I examined the rings themselves, they were not chewed up or mangled at all. They looked to be in basically perfect condition.
So new foam rings, new oil in the lowers, new grease, and the lowers slipped right on and now the fork feels good and plush. But I'm still not clear on exactly what happened. If pieces of foam came from the the previous service, they would have been super obvious. I removed the seals and the original foam and cleaned the insides of the lowers. I would have noticed chunks of foam sticking around in there. And yet..... last night, there they were.
Note - it may not look like it in the video, but those chunks are definitely pieces of foam. I picked them up and smooshed them and they were clearly torn up foam.