SERVICE PROCEDURES
2013-2015 FLOAT CTD Dish Rebuild
Required Parts
- 803-00-142 Kit: Rebuild, FLOAT Line Air Sleeve, Special Q-Ring
- 803-00-816 Seal Kit: CTD Boost Valve and Dish Shock Rebuild
Required Tools
- 398-00-227-A Tooling: Piston Tool Weldment [2X Ø.094 on .500 BC]
- 398-00-280 Tooling: Eyelet Torque Tool
- 803-00-805 Kit: Shaft Clamps, Shocks, CTD 9mm, 3/8in, 1/2in, 5/8in
- Nitrogen Fill Station (Tank with Regulator) required for full rebuild .
WARNING: Always wear safety glasses and protective gloves during service to prevent potential injury. Failure to wear protective equipment during service may lead to SERIOUS INJURY OR DEATH.
This service procedure guides you through the rebuild of a FLOAT CTD Boost Valve rear shock. For additional information and complete assembly drawings please visit FLOAT CTD Dish »
Some pictures used below show different models of shocks, but all procedural information is the same. Please use this service procedure for information regarding all FLOAT CTD Dish shocks.
WARNING: FOX products should be serviced by a qualified bicycle service technician, in accordance with FOX specifications. If you have any doubt whether or not you can properly service your FOX product, then DO NOT attempt it. Improperly serviced products can fail, causing the rider to lose control resulting in SERIOUS INJURY OR DEATH.
WARNING: Modification, improper service, or use of aftermarket replacement parts with FOX forks and shocks may cause the product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork or shock, including the fork brace (lower leg cross brace), crown, steerer, upper and lower leg tubes, or internal parts, except as instructed herein. Any unauthorized modification may void the warranty, and may cause failure or the fork or shock, resulting in SERIOUS INJURY OR DEATH.
WARNING: FOX suspension products contain pressurized nitrogen, air, oil, or all 3. Suspension misuse can cause property damage, SERIOUS INJURY OR DEATH. DO NOT puncture, incinerate or crush any portion of a FOX suspension product. DO NOT attempt to disassemble any portion of a FOX suspension product, unless expressly instructed to do so by the applicable FOX technical documentation, and then ONLY while strictly adhering to all FOX insturctions and warnings in that instance.
WARNING: Never attempt to pull apart, open, disassemble, or service a FOX shock that is in a "stuck down" condition. A "stuck down" condition results from a failure of the dynamic air seal (located between the positive and negative air chambers within the shock air sleeve), resulting with the negative chamber retaining a higher pressure than the positive chamber. To test whether the shock is in fact "stuck down":
- Remove the air cap and depress the Schrader valve, to completely release air pressure from the positive chamber of the shock.
- If your shock has an EVOL air sleeve, you must release air pressure slowly to stop from inducing a "stuck down" condition.
- If the shock body retracts into the air sleeve near bottom-out after the air is slowly released from the positive chamber, attach a FOX high pressure pump and pressurize the shock to 250 psi/ 17 bar).
- If your shock has an EVOL air sleeve, you must cycle the shock after every 50psi addition while filling.
- If the shock does not fully extend, it is in a "stuck down" condition.
WARNING: Any improper servicing procedure with FOX air shocks in the "stuck down" condition can lead to SERIOUS INJURY OR DEATH. Contact FOX or an Authorized Service Center for repair.
Disassembly
Step 10
Install a new pellet from the service kit, the flat side facing up, and secure with the pellet screw. Prefill the shock body with oil, pouring down its side to minimize possible aeration of the oil. Set the body aside in a vertical position and move on to the topcap, allowing time for trapped air to escape.
Eyelet Assembly
If you are servicing a FLOAT CTD Dish Remote shock, go to the CTD Remote Eyelet section »
Rebound and Compression Knobs and Final Assembly
Step 15
Before threading the body cap to the body, remove the bleed hole screw. Keeping the bleed hole at the high point, hand-tighten the body into the body cap from below, watching for air bubbles escaping the bleed hole. As you thread the two parts together, gently tap the body to help any trapped air to escape.
Step 19
Set the shock damper in Descend mode. Coat the air seals with a film of Float Fluid and start the air sleeve installation onto the body. Before threading the air sleeve to the eyelet, inject 2cc of Float Fluid into the main air chamber. Thread the air sleeve to the eyelet and tighten "hand-tight".