Rebuilding the Fox 36 Performance Elite suspension fork is essential for maintaining optimal performance, ensuring durability, and preventing premature wear. This model is known for its excellent stiffness-to-weight ratio and exceptional small bump compliance. A proper rebuild restores its smooth operation and protects the internal components from contamination and degradation over time.
Tools Required
- 10mm socket wrench
- 26mm and 32mm sockets
- Torque wrench [paid link]
- Plastic mallet
- Allen wrenches [paid link] (2mm to 6mm)
- Pick tool or dental pick
- Suspension grease
- Fox Gold 20wt and Float Fluid
- Clean rags
- Shock pump
- Oil pan
- Isopropyl alcohol (90% or higher)
Disassembly Procedure
Disassembling the fork properly is crucial before beginning the rebuild process. Begin by removing the front wheel and brake caliper to prevent accidental damage. Once the fork is removed from the bike, let all air out of the air spring via the Schrader valve using a pick to depress the core gently.
Next, remove the rebound knob using a 2mm Allen key and then loosen the lower bolts with a 10mm socket. Gently tap the bolts with a plastic mallet to dislodge the shafts inside. Drain the lower leg oil into a clean oil pan. Carefully slide the lower legs off the upper assembly. Take care not to damage the dust wipers or foam rings during this step, especially if they will be reused temporarily.
Inspection and Cleaning
Inspect all internal parts including the air shaft, damper cartridge, and lower legs. Look for scoring, contamination, or wear. Remove the foam rings and seals from the lower legs. Soak the lower legs in isopropyl alcohol to dissolve any built-up grime or oil residue. Clean stanchions with a lint-free rag. Replace any worn or deformed seals or rings with OEM replacements.
Clean the air shaft, piston bands, and damper shaft. Check for smooth action in the damper. This is a good opportunity to inspect the damper for oil leaks and air spring for performance degradation, which might indicate a need for further service.
Air Spring Maintenance
Remove the air top cap using a 26mm socket. Pull out the air shaft and clean it thoroughly. Inspect the piston bands and replace them if worn. Apply a light layer of suspension grease to the new seals before installation. Reinsert the air shaft and torque the top cap to manufacturer specifications using a torque wrench [paid link].
Apply Float Fluid to the air shaft to ensure proper lubrication on startup. Do not overfill. Over-lubrication can cause air migration or harsh bottom-outs.
Damper Side Preparation
If you’re performing a full damper service, remove the damper assembly using a 32mm socket. Ensure no oil spills into your workspace. Check for fluid contamination or signs of aeration. Replace the oil with the correct volume of 20wt Gold oil, then reinstall the damper unit. Torque to spec and double-check the damper rebound and compression adjusters function correctly after reassembly.
Lower Legs Reinstallation
Lubricate the foam rings and insert them into the lower legs. Apply a thin coating of suspension grease to the new dust wipers. Carefully slide the lower legs back onto the stanchions. Pour 10cc of 20wt Gold oil into each leg before sealing.
Reinstall the lower bolts and torque them according to Fox’s torque specs. Reattach the rebound knob and ensure smooth rotational action. Pressurize the fork using a shock pump to your preferred setting. Reinstall the fork onto the bike and remount the brake caliper and wheel.
Performance Optimization Tips
After rebuilding the 36 Performance Elite fork, you can fine-tune performance further. Adjust sag to approximately 20-25% of total travel for trail use. Set low-speed compression to enhance pedaling efficiency. Use volume spacers inside the air spring to adjust progressiveness based on rider weight and trail preference.
Consider using low-friction seals if frequently riding in wet or muddy environments. Routine maintenance, such as wiping stanchions and checking air pressure weekly, ensures prolonged high performance and fewer full rebuilds.
Troubleshooting Post-Rebuild Issues
If you experience a harsh top-out, it could be due to insufficient Float Fluid in the air spring. A soft or diving fork typically indicates under-inflation or oil loss. Any loud squelching or inconsistent damping points to possible air contamination in the damper, requiring a bleed or complete damper rebuild.
Fork not returning fully could indicate an air transfer issue between the positive and negative chambers. Always verify that the air spring assembly was reinstalled correctly, and seals are not inverted or pinched.
Compatibility Considerations
The 36 Performance Elite is compatible with a wide range of modern mountain bike chassis. However, it is designed to work best with Fox’s own damper and air spring systems. Avoid mixing internals from different fork generations unless explicitly allowed by Fox.
Ensure the axle type and offset match your frame and wheel setup. The fork’s GRIP2 damper system requires precise alignment and torque values to maintain intended damping characteristics. Always cross-reference part numbers when replacing internal components to ensure full compatibility.
Comparison with Similar Forks
Compared to the Fox 36 Factory, the Performance Elite shares the same chassis and damper architecture but lacks the Kashima coating. This makes it slightly less smooth in initial sensitivity but more cost-effective.
When matched against RockShox Lyrik Ultimate, the 36 Performance Elite offers similar stiffness but arguably better small bump compliance and greater adjustability in its GRIP2 damper. Riders focused on tuning flexibility will appreciate the independent high- and low-speed compression and rebound adjustments.
Maintenance Intervals and Best Practices
For regular riders, lower leg service should be performed every 30 to 50 hours of riding. A full rebuild, including damper and air spring, is recommended every 100 hours or annually—whichever comes first.
Use only OEM Fox parts and fluids to ensure compatibility and performance. Keep a maintenance log to track service intervals and part replacements. Always follow the torque specifications and avoid using power tools for sensitive components.
Final Setup and Safety Check
After completing the rebuild, cycle the fork a few times to ensure even oil distribution. Check for any leaks at the seals or damper interfaces. Verify all bolts are torqued to spec and rebound and compression settings are dialed in to your preference.
Test ride the bike slowly at first, feeling for consistent rebound and compression action. Listen for unusual noises and recheck air pressure after the fork has settled.
A properly rebuilt Fox 36 Performance Elite suspension fork will provide renewed responsiveness, support, and trail feedback, ensuring a more confident and controlled ride.