Disassembly of the shaft assembly

1. Place the assembly into the clamp block and place in the vice. 14mm and 22mm klem blocks are available.
2. For shocks with new style rebound adjusters, you must make sure the rebound adjustment is closed. Hold the 3mm allen wrench and remove the 13mm nut. 3. Using a 15mm wrench, remove the nut holding the piston assembly on the shaft. Newer assemblies use a 19mm wrench.
4. Carefully remove the pieces of the piston assembly starting with the rebound shim stack. Make sure to keep the pieces in order as they are removed.
5. Place the pieces on a clean working surface like a paper towel or butcher paper. Make sure to disassemble in the order they will be going back together.

Service Guides

• Checking nitrogen pressure and installing a new fill plug
• Removing the top guide and shaft assembly
• Disassembly of the shaft assembly
• Assembly of the shaft assembly
• Installing shaft assembly into shock (floating piston set)
• Installing springs on 5000 Series
• Installing Top Mounts on 5200s and 5300s
• Purging Air from 2 and 3 way 5000 Series Dampers
• Installing the bottom guide for AST 4200s
• Appendix A - Basic Servicing Tools Required