




Here's what I did (You are going to need a reasonable amount of experience of taking stuff apart, this is not for beginners. But it's not super complex either)
- Release air pressure, then remove valve cores to ensure there is no trapped pressure on the air side
- Stroke the shock by hand, if it still has some spring action then there's air pressure on the oil side. I get the same problem on DHX-A. I carefully/slowly loosened the two screws that hold the body together, and allowed the oil/air to bleed out. The set screw in the body (next to the rebound knob) might be a better way to bleed the pressure. My shock had lots of air on the oil side, which is probably why the rebound damping was getting sketchy.
- Remove the 2 screws to separate the body
- Unscrew the large shaft nut and remove the shaft assy
- Unscrew the piston from the shaft. I heated the piston to soften the loctite. I didn't have the factory pin spanner so I used pipe grips and filed smooth the damaged bit of piston after reassembly. Dont damage the piston in the area of the seal or bearing strip.
- Remove the wiper seal and quad ring from the shaft nut, being very careful not to scratch the seal cavities. These seals will probably have dirt in them, so even if you don't replace them they should still be removed and cleaned.
- The piston seal looked a bit worn, and I should have gone to a local hydraulic seal supplier to get a new one. But it was the weekend to I reused the old one....
- The rebound knob assembly screws out by turning its large hex.
- Turning the rebound knob allows further disassembly of the rebound assembly. But because the old oil was clean and things weren't leaking, I didn't completely strip everything down.
- The small spring that holds up the "platform" damping pin was broken in 2 (pictured), which is not a good sign. I scrapped the short bit and stretched the remaining bit to make it about the same length as the original spring.
- Remove the caps for the internal floating pistons (IFP), and loosen the bleed screw in the piston
- Now clean everything. Hydraulic assemblies such as this need to be very clean. Make sure your workspace and tools are clean.
- Reassemble the shock, except leave the caps off the IFP chambers, and don't fit the valve cores
You now need to refill and bleed the shock. 7wt oil seemed right, compared to the old oil that was tested by putting 1ml of oil in a syringe body and counting how fast the oil dripped out. I used 50ml of oil. - Have a block of wood on the bench so that when you push down on the shock body you actuate the travel adjust lever. You'll need this since the travel adjust prevents oil from moving into the IFP chambers.
- You probably want the IFPs about 1/2 way down the chamber at this stage, but don't worry about it. Remove a bleed screw from an IFP and squirt oil in the hole. Actuate the travel adjust lever then stroke the shaft to get oil in and air out. repeat for the other IFP.
- Continue moving oil around inside the shock and removing air and adding oil, by moving the IFPs and shaft. Once you have the air out then the the shock will lockout solid. If the locked out shaft is at all spongey then there is air in the oil.
- The final bit is setting the oil volume to the correct level. I don't know what this is so I did some thinking about it, and this is what I suggest:
- With the bleed screws fitted, push both IFPs as far down as you can. There must be enough oil so that the shaft fully extends before both IFPs have bottomed out. You can check that the IFPs are not bottomed by actuating the travel adjust lever then pushing down on one IFP; the other IFP will move off its bottom (the shaft must be at full stroke). When riding the shaft is going to extend a bit more against its rubber bumper. I put enough oil in so that the IFP was 5mm from bottoming out. If the oil volume is too small then the IFPs will bottom out and the shock won't fully extend. If there's too much oil then the shock will ramp up to fast at the end of its travel. If you know the factory IFP level (oil volume) then please post it.




Edit: Tried to re-post the images, but can't figure it out, sorry. Uploaded the images but that's as far as I got.