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Possible to change fork seals over inner tube?

Discussion in 'XJ Technical Chat' started by Beekman, Mar 11, 2015.

  1. Beekman

    Beekman XJ Grasshopper

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    So here I am, need to change the fork seal on my front right fork. I pull it off, have a friend help me remove top cap and get spring out, oil is all nice and drained. But you guessed it, damper rod retaining bolt is giving me trouble. Mostly the fact that the top of the damper rod, where my home made damper rod tool should fit in, is STRIPPED :confused::confused::confused:. I noticed it first time i shined a flashlight down there, "why is there no star pattern there for my tool to hold into?". I put the tool down and i can feel the bumps where the tool should be grabbing. Ive tried the tool, broomsticks, dowel, putting the spring back in for pressure, having two people pull on the inner tube to try and hold the damper, and still the bolt just spins.

    Which leads me to my question, is there a reliable way to remove the fork seals over my inner tube without damaging it? Not my ideal choice but desperate times...
     
  2. FtUp

    FtUp Well-Known Member

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  3. PilotSmack

    PilotSmack Active Member

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    I fully support a rebuild, and like FU suggested, I used a broomhandle with duct tape on it and an impact wrench.

    That said, if you have replacement seals, can't you just use an Xacto and cut into the seals and then remove them, and slide the new ones down the tube to their new home? I know, way less than ideal, purely as a last resort idea.
     
  4. Beekman

    Beekman XJ Grasshopper

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    Ill give the impact wrench a shot, nice to see that there's some cheap pairs out there too in case the worst happens.
     
  5. MiCarl

    MiCarl Active Member

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    You'll have a better chance with the impact if you reinstall the spring first. The spring pressure helps keep the damping rod from turning.

    Worst case you can carefully drill the head off the bolt. A replacement bolt would probably be less money than a fork.
     
  6. ThinkingTime

    ThinkingTime Member

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    I second what MiCarl said. I've had good success removing the bottom allen key with the fork spring and top cap still in place. I usually crack it loose before I remove the fork from the triple trees. Be aware that you'll lose some fork fluid using this method, so have some rags handy.
     
  7. Polock

    Polock Well-Known Member

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    i think they put some thread lock on that bolt from the factory, some heat on the allen head might help
     
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  8. jmilliken

    jmilliken Well-Known Member

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    Yea. There is supposed to be thread lock on those bottom bolts.
     
  9. Beekman

    Beekman XJ Grasshopper

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    Got out with the impact thanks guys
     
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  10. Beekman

    Beekman XJ Grasshopper

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    Is it necessary to loctite the Allen bolt again on reinstallation?
     
  11. FtUp

    FtUp Well-Known Member

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    yes

    FU
     
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  12. chacal

    chacal Moderator Moderator Supporting Vendor Premium Member

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    I would use the purple "semi-permanent" locking fluid this time..........rather than the red "permanent" locking fluid.
     

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