The Fox 38 Performance Elite suspension fork is engineered for aggressive enduro and trail riding, delivering top-tier performance with robust chassis stiffness, excellent damper control, and fine-tuned adjustability. Rebuilding this fork is essential for maintaining its precision and extending its lifespan. This guide walks you through the complete rebuild process, from preparation to reassembly, focusing exclusively on the Fox 38 Performance Elite.
Tools Required
- 32 mm socket and torque wrench [paid link]
- Flathead screwdriver or pick tool
- Allen keys [paid link] (2 mm to 6 mm)
- Soft-face mallet
- Fork-specific seal driver set
- Fox 20cc Float Fluid
- Fox Gold 20wt oil
- Clean rags and isopropyl alcohol
- Suspension grease
- Nitrile gloves
- Fox Rebuild Kit for 38 Performance Elite
Fork Overview and Key Features
The 38 Performance Elite shares the same chassis as the Factory model but lacks the Kashima coating. It features the GRIP2 damper, offering high and low-speed compression and rebound adjustability. With a floating axle and bleed valves, the fork is designed for precision and reduced stiction. The 38mm stanchions deliver stiffness for aggressive riding while maintaining responsive suspension action.
Disassembly: Preparing for the Rebuild
Start by cleaning the fork thoroughly. Use a soft brush and isopropyl alcohol to remove dirt and grime. Once dry, remove the front wheel and brake caliper. Detach the fork from the bike frame and place it on a clean workbench.
Using a 2 mm Allen key, carefully remove the rebound knob and air cap. Release air from the air spring by pressing the Schrader valve. Remove the lower leg bolts with a 6 mm Allen key and tap them with a mallet to dislodge the legs. Pull the lowers off gently, catching any oil that drains.
Cleaning and Inspection of Internal Components
Thoroughly inspect internal components for signs of wear, including scratches on the air shaft, damper shaft, or stanchions. Clean all parts with isopropyl alcohol and dry with lint-free rags.
Pay special attention to the air spring assembly. If the fork hasn’t been serviced in 50+ hours of riding, seals and foam rings should be replaced. Replace wiper seals using a seal puller, and clean the inside of the lower legs thoroughly before installing new foam rings.
Installing New Seals and Foam Rings
Apply a small amount of suspension grease to the new foam rings and seat them in the lower legs. Use the Fox-specific seal driver to press in new dust wipers. Ensure they are seated evenly and fully flush with the casting surface.
Pre-lube the foam rings with a few drops of 20wt Gold oil to improve lubrication during initial use.
Air Spring Maintenance and Reassembly
Remove the air spring assembly using a 32 mm socket. Once removed, clean all parts and replace the inner seals as per the rebuild kit instructions. Grease O-rings lightly and reassemble the air spring. Install it back into the stanchion and torque the top cap to the manufacturer’s specifications.
Apply 20cc of Float Fluid into the air chamber for optimal sealing and lubrication before sealing the cap.
Damper Maintenance and Reinstallation
While damper servicing typically requires more advanced tools and vacuum bleeding equipment, basic maintenance can be performed. Clean and inspect the damper shaft for oil residue or contamination. If there’s no leakage, leave the damper sealed. Otherwise, consider a full service or replacement if unsure.
Reinstall the damper side top cap and torque it as per specifications.
Reinstalling the Lower Legs
Before reinstalling, add 40cc of 20wt Gold oil into each lower leg to lubricate bushings and stanchions. Align the lowers with the stanchions and carefully slide them up, avoiding damage to new seals. Tap the bolts gently with a mallet to seat the lowers, then tighten them to spec.
Install the rebound knob and torque it gently to avoid stripping the set screw.
Final Checks and Air Pressure Reset
Once the fork is reassembled, reinflate the air spring to your preferred pressure. Check that rebound and compression dials function smoothly. Compress the fork to circulate lubricant and settle the seals. Listen for any unusual noises and ensure smooth travel throughout the stroke.
Reinstall the fork onto your bike and torque the axle to factory spec using the floating axle system to eliminate bind.
Common Setup and Performance Issues
Improper oil volumes or dry foam rings can cause harsh travel and stiction. Be sure oil measurements are precise and foam rings are fully saturated.
If the fork feels inconsistent after a rebuild, double-check that the air spring is fully seated and the damper is torqued properly. Inadequate torque on the top caps can cause pressure loss or poor damping response.
Over-tightening the lower leg bolts may cause binding. Ensure they’re snug but not over-torqued.
Optimization Tips for Performance
Experiment with volume spacers to tailor mid-stroke support and bottom-out resistance. The Fox 38 Performance Elite is compatible with various volume tokens, offering tunability for different terrain and rider weight.
Fine-tune the GRIP2 damper’s compression and rebound settings in 1–2 click increments. Take note of changes after each ride to identify optimal setup.
Keep the stanchions and seals clean post-ride to reduce long-term wear and maintain smooth travel.
Compatibility Considerations
The Fox 38 Performance Elite is designed for modern long-travel 29” and 27.5” trail and enduro bikes. It is compatible with boost spacing hubs (15x110mm) and uses a floating axle system. Ensure hub compatibility and brake rotor diameter (up to 203 mm) for safe operation.
It works seamlessly with Fox’s air volume spacers and remote lockout add-ons if supported by the specific damper.
Model Comparisons and Alternatives
Compared to the Fox 38 Factory, the Performance Elite omits the Kashima coat but retains the same internals and chassis. Riders prioritizing durability and feel may find minimal differences in performance but a noticeable price advantage.
Against the Fox 36, the 38 offers increased stiffness and is better suited for aggressive enduro riding. However, the 36 remains a strong option for lighter riders or trail-focused bikes.
RockShox ZEB is the closest competitor, with comparable stiffness and damper performance, but Fox’s GRIP2 offers finer tunability in compression control.
Frequently Asked Questions
How often should I rebuild the Fox 38 Performance Elite fork?
Fox recommends a lower leg service every 50 hours of riding and a full rebuild every 125 hours or annually.
What oil should I use for my 38 Performance Elite fork?
Use 20wt Gold in the lower legs and 20cc Float Fluid in the air spring chamber.
Can I upgrade my Performance Elite to a Factory model?
While they share internal compatibility, upgrading to Factory means replacing the entire stanchion assembly with Kashima-coated parts, which is not cost-effective.
What torque settings should I use on the top caps and axle?
Refer to the official Fox service manual for specific torque values: typically, 50–60 in-lbs for top caps and 19–22 N-m for the axle.
Why does my fork feel sticky after a rebuild?
This usually results from dry seals or under-lubricated foam rings. Reapply 20wt Gold oil and cycle the fork to redistribute lubrication.
Is the GRIP2 damper user-serviceable?
Basic cleaning and inspection are possible, but a full service requires vacuum tools and experience. If leaking or underperforming, professional service is recommended.