The Fox 32 Float Factory Step-Cast is one of the most advanced cross-country suspension forks on the market, offering lightweight performance without compromising rigidity or control. Over time, even top-tier forks like the 32 Float require internal servicing to maintain optimal function. This step-by-step guide details the complete rebuild process, including disassembly, cleaning, reassembly, and tuning tips for better performance.
Whether you’re a home mechanic or an experienced shop technician, following these instructions will ensure your fork continues to deliver precise damping and consistent rebound.
Tools Required
- Torque wrench [paid link] (0-20 Nm range)
- 10mm socket or open wrench
- 26mm socket
- 32mm socket
- Pick tool
- Flat-blade screwdriver
- Rubber mallet
- Fox 5 wt. Teflon-infused suspension fluid
- Fox Float Fluid
- Clean measuring cup or syringe
- Isopropyl alcohol (90%+)
- Clean lint-free rags
- New dust wipers and seals
- Fox seal driver kit
- Fork-specific damper removal tool (for FIT4 or GRIP dampers)
- Suspension grease
Understanding the Fork’s Internal Design
The 32 Float Factory Step-Cast fork utilizes a narrow crown width and cutout lowers to minimize weight while maintaining structural integrity. Inside, the fork features a FIT4 or GRIP damper cartridge and a separate air spring assembly. These two systems are independent, allowing individual servicing of each side.
The right leg houses the damper, while the left contains the air spring. Both systems share the lower legs, which contain bath oil and dust seals that need periodic replacement.
Preparation and Initial Setup
Before beginning the rebuild, clean the exterior of the fork thoroughly to prevent contamination during disassembly. Secure the fork in a workstand with adequate lighting. Release all air from the air spring using the valve on the top of the left leg. Remove the fork from the bike and place it horizontally on a clean workspace.
Removing the Lower Legs
- Start by removing the rebound knob on the bottom of the right leg.
- Use a 10mm wrench to loosen and remove the damper shaft nut.
- On the left leg, remove the air shaft nut using a 10mm wrench.
- Use a rubber mallet to tap the bolts to release the shaft ends from the lower leg.
- Once released, gently slide the lowers off the fork’s upper tubes.
Inspect the removed bath oil; if it’s discolored or contaminated, it indicates the fork was overdue for service. Clean the inside of the lowers with isopropyl alcohol.
Replacing Dust Wipers and Seals
Use a flat-blade screwdriver and pick tool to remove the old dust wipers and foam rings. Carefully clean the seal bores with alcohol. Lightly grease the new foam rings with suspension grease and seat them in place. Insert the new dust wipers using the Fox seal driver, ensuring an even press without damaging the seals.
Servicing the Air Spring
- Remove the air top cap using a 26mm socket.
- Extract the air shaft assembly and inspect the internal O-rings and piston.
- Replace worn O-rings and clean all surfaces.
- Reapply Fox Float Fluid to the main piston and reinsert the shaft into the stanchion.
- Torque the top cap to the manufacturer’s spec (typically 22-25 Nm).
Servicing the Damper (FIT4 or GRIP)
For FIT4:
- Remove the damper top cap with a 32mm socket.
- Use the Fox-specific damper tool to pull the damper out of the stanchion.
- Inspect oil and replace with 5 wt. Teflon-infused suspension fluid as per Fox’s recommended volumes.
For GRIP:
- GRIP dampers are sealed and not user-serviceable without replacement parts.
- If necessary, replace the entire cartridge or send to Fox for a factory rebuild.
After inspection or fluid replacement, reinstall the damper and torque the top cap correctly.
Reinstalling the Lower Legs
- Pour the recommended amount of 5 wt. oil into each lower leg.
- Carefully slide the lowers onto the upper tubes, ensuring the wipers seat evenly.
- Reattach the shaft nuts and torque to spec (typically 5-7 Nm).
- Reinstall the rebound knob.
Refilling and Setting Air Pressure
Re-inflate the air spring using a shock pump to your desired riding pressure. Fox recommends setting sag between 15% and 25% for cross-country use. Check rebound and compression knobs for smooth function. Rotate through all damping settings to ensure no binding or sticking.
Performance Optimization Tips
For racers or aggressive trail riders, reducing friction in the air spring assembly with upgraded O-rings or aftermarket seals can enhance sensitivity. Additionally, custom tuning of the FIT4 damper by adjusting shim stacks can yield firmer or plusher behavior depending on terrain preferences.
Riders may also benefit from using volume spacers in the air chamber to alter the progression curve of the fork. Fewer spacers make the fork more linear, while more spacers increase bottom-out resistance.
Troubleshooting Common Issues
Fork feels sticky or harsh over small bumps:
Likely due to dry foam rings or worn wiper seals. Ensure proper lubrication and replace seals as needed.
Loss of air pressure overnight:
Indicates a leaking air piston seal or Schrader valve. Rebuild the air spring and inspect all O-rings.
Inconsistent rebound or damping fade:
May point to contaminated or low damper oil. Replace damper oil and check internal cartridge condition.
Top-out clunk during extension:
Usually due to low negative air pressure or loose air shaft assembly. Confirm internal air balance and retorque shaft nuts.
Compatibility with Other Components
The 32 Float Factory Step-Cast is designed for 100mm travel and works best with lightweight XC frames and wheels. It uses a 15x110mm Boost axle and fits 29” wheels. Ensure brake calipers are compatible with the flat-mount or post-mount design. The fork is not suited for aggressive trail or enduro riding due to its narrow chassis.
Comparison with Similar Fork Models
Compared to the Fox 34 Step-Cast, the 32 offers superior weight savings but slightly less stiffness. Riders needing more aggressive handling may prefer the 34 for better steering precision. Against the RockShox SID SL, the Fox 32 provides more damper tuning options but is slightly heavier.
Riders seeking maximum adjustability should consider the FIT4 version, while those wanting simpler setup might opt for the GRIP model.
Conclusion
Rebuilding your Fox 32 Float Factory Step-Cast fork is a critical maintenance step that restores performance and extends the life of your suspension. With proper tools and attention to detail, home mechanics can perform a complete service that rivals professional shop work. Regular maintenance every 125 hours or yearly (whichever comes first) ensures consistent damping, smoother small-bump sensitivity, and a more controlled ride feel.