SERVICE PROCEDURES
2025 FLOAT X LIVE VALVE NEO Rebuild
Required Parts
- 025-03-063 Oil: Suspension Fluid, 4 WT, 1.0 Liter Bottle
- 803-01-996 Seal Kit: 2025 Float X Live Valve Neo Damper Rebuild Kit
Required Tools
- 398-00-280 Tooling: Eyelet Torque Tool
- 398-00-558 Tooling: Pin Spanner Wrench
- 398-00-951 Tooling: Torque Fixture, 54mm Trunnion Eyelet, Tall
- 803-00-805 Kit: Shaft Clamps, Shocks, CTD 9mm, 3/8in, 1/2in, 5/8in
- 803-01-691 Kit: Tooling, .210-36 Vacuum Oil Fill, 2022 Shock, Andreani Thread, with O-ring
- 803-04-055 Kit: Tooling: Rear Shock, Air Fill Adaptor Assembly, 2024
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.
NOTE: As many assemblies are shared between the FLOAT X Live Valve Neo and standard FLOAT X and DHX shocks, some images in this rebuild procedure may show a FLOAT X or DHX shock. Please follow all instructions in this rebuild as they are for FLOAT X Live Valve Neo shocks.
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, 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, connect your FOX high-pressure pump to the Schrader valve, then slowly release all air pressure from the positive chamber of the shock.
- If the shock body retracts into the air sleeve near bottom-out after the air is released from the positive chamber, attach a FOX high-pressure pump and pressurize the shock to 250 psi (17 bar).
- If the shock does not fully extend, it is in a “stuck down” condition.
- Any attempt to service FOX air shocks in the “stuck down” condition can lead to SERIOUS INJURY OR DEATH. Contact FOX or an Authorized Service Center for repair.
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, shocks, and seatposts may cause the product to malfunction, resulting in SERIOUS INJURY OR DEATH. DO NOT modify any part of a fork, shock, or seatpost 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 products contain pressurized nitrogen, air, oil, or all 3. Misuse can cause property damage, SERIOUS INJURY OR DEATH. DO NOT puncture, incinerate or crush any portion of a FOX product. DO NOT attempt to disassemble any portion of a FOX 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.
NOTE: Only use FLOAT X Live Valve Neo specific volume spacers in FLOAT X Live Valve Neo shocks. Usage of volume spacers intended for other products may cause internal damage that could require replacement of the eyelet assembly or other components.
NOTE: Do not overtighten the air valve core when reinstalling into the eyelet if it has been removed. Thread the air valve core in clockwise until the plunger of the air valve core is 0.010"-0.040" below the level of the Schrader valve housing.
Disassembly
Step 1
Make sure the Live Valve Neo battery has been removed and replaced by the dummy battery to protect the controller during the rebuild. Remove the black air cap and thread on your FOX shock pump. Slowly release all air from the main air chamber with your pump, then remove the pump. Verify that all air has been released by depressing the Schrader valve.
WARNING: Please verify that all air has been released from the air chamber by pushing down on the Schrader valve core. Failure to release all air pressure before further disassembly may cause parts to eject causing SEVERE INJURY OR DEATH.
Step 2
Unthread and remove the air sleeve from the eyelet by turning it counter-clockwise.
Step 3
Replace the seals in the end of the air sleeve with new greased ones from the rebuild kit as shown. Set aside in a clean area once complete.
Step 4
Unthread the Air Fill Cap counter-clockwise with a T8 Torx driver then set it aside. Thread the MY22 Air Fill Adaptor (PN: 803-01-692) clockwise into the Reservoir End Cap fully to release the IFP pressure (if attached to a FOX high-pressure pump, use the pump to bleed out all air from the reservoir). Remove the Air Fill Adaptor by unthreading it counter-clockwise.
Step 5
Push the Reservoir End Cap into the Reservoir to gain access to the wire retaining ring. Remove the wire retaining ring by pushing the center of the ring down which will cause the ends of the ring to pop up. Be careful not to scratch the IFP bore while removing or installing this ring. Use a small hex wrench to lift the Reservoir End Cap out from the Reservoir.
Step 6
Hold the flats of the IFP with needle-nosed pliers while you unthread the IFP bleed screw counter-clockwise with a T15 Torx driver. Remove the bleed screw then remove the IFP by pulling up with needle-nosed pliers.
Step 7
Pour out any oil from the reservoir into your waste oil basin. Clamp the body eyelet in your soft jawed vise.
Step 8
Remove the bearing housing cap and any travel spacers (if present) by unthreading counter-clockwise and removing the two screws with a 2mm hex wrench. Lift the bearing housing cap to expose the pin spanner holes in the bearing assembly.
Use the Pin Spanner Wrench (PN: 398-00-558) to unthread the bearing housing assembly counter-clockwise.
Step 9
Pour the oil from the body into your waste oil basin. Clamp the adjuster eyelet in your soft jawed vise.
Step 10
Unthread the piston bolt counter-clockwise with a chamfer-less 15mm socket. Remove the entire main piston valving assembly then remove the topout o-ring.
Step 11
Remove the bearing housing assembly followed by the bearing housing cap, bottom out bumper, and bottom out plate. Some shocks may use an o-ring as the bottom out bumper. In shock that use an o-ring as the bottom out bumper, a bottom out spacer is required in addition to the plate and o-ring. Remove any shaft travel spacers if present.
Step 12
Remove the air sleeve o-ring within the eyelet. Remove the rebound rod by pulling it up out of the shaft. Verify that the 1.5mm ball bearing is in place at the end of the rebound rod.
General Reassembly
Step 1
Clamp the shaft eyelet in your soft jawed vise then install a new greased air sleeve o-ring from the kit into the eyelet. Reinstall the bottom out plate.
Step 2
Install a new bottom out bumper from the kit (shown). In some cases this might be an o-ring and spacer, replace the o-ring with a new greased one from the kit. Reinstall the bearing housing cap making sure to orient the counter-bores on the cap toward the eyelet.
Step 3
Replace the quad ring and backup rings on the bearing housing assembly. Note the original configuration (default or flipped) of the thick and thin backup rings and replace the new ones in their original configuration. Replace the o-rings within the bearing housing assembly with new greased ones from the kit. NOTE: The shaft sealing o-ring within the bearing housing is the black rubber o-ring in the rebuild kit. Reinstall the bearing housing assembly onto the shaft as shown. Install a new greased topout o-ring (the yellow poly o-ring) from the kit onto the shaft.
Step 4
Remove the topout plate from the valving assembly then remove the compression valving assembly, main piston, and rebound valving assembly. Inspect the shims and replace any with damage.
Step 5
Reinstall the rebound valving assembly onto the piston bolt followed by the main piston. Note the orientation of the main piston as shown. Reinstall the compression valving assembly followed by the topout plate. Make sure that no shims are off center or pinched.
Step 6
Replace the two o-rings on the rebound rod with new greased ones from the kit as shown. Make sure that the ball is present in the end of the rod. Coat the ball end of the rod with a thick film of Ultraplex LT2 or Stay Lube SL3125 blue waterproof grease.
Step 7
Reinstall the rebound rod into the shaft with the ball end first. Push down on the rebound rod while you turn the red rebound knob counter-clockwise until you feel the stop. This verified that the rebound rod is fully seated in the groove of the rebound knob and that the rod won't be pinched when tightening the piston bolt later.
Step 8
Reinstall the main piston assembly onto the shaft taking care not to pinch any shims while threading the piston bolt clockwise. Tighten the piston bolt clockwise to 80 in-lb (9.0 Nm) torque with a 15mm chamfer-less socket.
Step 9
Replace the o-ring on the IFP with a new greased one from the kit. Coat the inside wall of the reservoir with a thin film of FOX 4 wt. oil. Reinstall the IFP into the reservoir. Reinstall the bleed screw with new greased o-ring from the kit into the IFP, tightening clockwise to 7in-lb (0.8 Nm) torque while holding the flats of the IFP. Reinstall the wire retaining ring into the groove in the reservoir as shown.
Step 10
Clamp the body in your soft jawed vise then reinstall the shaft assembly tightening the bearing housing clockwise to 240 in-lb (27.1 Nm) torque. Use the Pin Spanner Wrench (PN: 398-00-558) to tighten the bearing housing clockwise (shown).
Step 11
Reinstall any travel spacers that were removed earlier. Reinstall the two screws that retain the bearing housing cap (if removed previously). Tighten clockwise to 10 in-lb (1.1 Nm) torque with a 2mm hex wrench.
Vacuum Bleed/Fill and Final Assembly
Step 1
Open all adjuster by turning them fully counter-clockwise. Remove the oil fill plug by turning it counter-clockwise with a T8 Torx driver. Make sure that your vacuum bleed machine is filled with FOX 4wt. oil (PN 025-03-063). Install the vacuum fitting (PN 803-01-691) into the body fill port by turning it clockwise. Cycle the shock by hand while you perform the vacuum cycle. Repeat as necessary to purge all air from the shock. Set the IFP to the appropriate depth based on the length of your reservoir.
Step 2
Orient the oil fill port so it is the highest part of the shock. Remove the vacuum fitting and reinstall the oil fill plug with new greased o-ring from the kit. Tighten clockwise to 8 in-lb (0.9 Nm) torque.
Step 3
Remove the wire retaining ring by pushing the center of the ring down which will cause the ends of the ring to pop up. Be careful not to scratch the IFP bore while removing or installing this ring. Coat the inside of the reservoir with a thin film of FOX 4wt. oil. Replace the o-ring of the reservoir end cap with a new greased one from the kit. Reinstall the reservoir end cap into the reservoir pushing down to allow for installation of the retaining ring.
Step 4
Reinstall the wire ring. Use a small hex wrench to lift the reservoir end cap into place making sure to orient the fill port away from the damper body. Install the air fill adaptor by threading it in clockwise. Set the IFP pressure to 150 psi. Remove the air fill adaptor while still attached to your pump. Reinstall the air fill cap with a new greaswed o-ring from the kit, tightening clockwise to 3 in-lb (0.3 Nm) torque.
Step 5
Coat the main air seal and backup rings on the bearing assembly with a thin film of FOX 20wt. gold oil. Coat the seals and backup rings in the end of the air sleeve with a thin film of FOX 20wt. gold oil.
Step 6
Begin to reinstall the air sleeve assembly onto the shock damper. Add 2cc of FOX 20wt. gold oil into the positive air chamber. Push the air sleeve assembly to the eyelet then tighten clockwise until hand tight. Add air to your desired pressure then reinstall the black air cap. Clean the exterior of the shock then dyno test all functions.
