Step-by-Step: Rebuilding Your Float 38 Factory Orange Suspension Fork

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The Fox Float 38 Factory Orange [paid link] is a high-performance suspension fork designed for aggressive riders who demand superior control and handling. Whether you’re looking to restore your fork’s performance after a season of heavy use or you simply want to ensure it operates at its peak [paid link], this guide will walk you through the process of rebuilding your Fox Float 38 Factory Orange [paid link] suspension fork. We’ll cover everything from disassembly to reassembly, as well as maintenance tips to optimize its performance.

Tools Required

  • 5mm and 6mm Allen wrenches [paid link]
  • 8mm Allen wrench [paid link]
  • Torque wrench [paid link]
  • Fox-specific suspension fluid (Float fluid)
  • 10mm socket
  • Suspension grease
  • Fork seal press
  • Needle nose pliers
  • Cleaning rags
  • Fork fluid syringe (for oil refills)
  • Fox Float 38 tool kit (optional but recommended for specific parts)

Disassembly Process

Removing the Fork from the Bike

Before beginning the rebuild process, you must remove the fork from your bike. This involves the following steps:

  1. Detach the front wheel by loosening the quick release or through axle, depending on your fork model.
  2. Remove the brake caliper if it’s attached to the fork. Use an Allen wrench [paid link] to remove the bolts.
  3. Loosen the stem bolts to release the fork from the headset.
  4. Pull the fork out of the frame, making sure to carefully set it aside in a stable location.

Disassembling the Lower Legs

  1. Remove the bottom bolts using a 5mm Allen wrench to remove the lower leg bolts.
  2. Separate the lower legs from the fork by gently pulling them away from the upper assembly.
  3. Drain any remaining fluid by tilting the fork over a rag and allowing the oil to drain fully.

Removing the Damper and Air Spring Assembly

  1. Remove the air spring assembly by loosening the top cap of the fork and pulling it out.
  2. Disconnect the damper by loosening its top bolts with a 6mm Allen wrench, ensuring you don’t damage the damper tube while removing it from the upper stanchion.

Cleaning and Inspection

With the fork disassembled, it’s time to clean and inspect each component.

  1. Clean all parts with a rag and suspension fluid. Avoid using harsh chemicals that can degrade the seals and oil seals.
  2. Inspect the stanchions for any scratches or damage. These can severely affect performance and lead to leaks if not addressed.
  3. Check the seals and wipers for wear and tear. If they appear damaged or worn, they must be replaced.

Rebuilding Process

Preparing the New Seals and Oil

  1. Lubricate the seals with suspension grease to ensure smooth operation once reassembled. Apply a thin layer to the inside of the fork legs and to any seals that contact the stanchions.
  2. Prepare the fork fluid by filling the appropriate amount into a syringe. Follow Fox’s recommended fluid amounts for both the damper and air spring.

Installing the Air Spring Assembly

  1. Insert the air spring assembly into the upper stanchion. Align it correctly and make sure it sits flush within the fork.
  2. Tighten the top cap securely using a 10mm socket. Be sure not to overtighten, as this can cause damage to the air spring assembly.

Installing the Damper

  1. Insert the damper back into the upper stanchion. Carefully feed it into place, ensuring that it seats properly in the air spring.
  2. Secure the damper bolts using a 6mm Allen wrench, ensuring they are tight but not over-torqued. Consult the torque specifications in the Fox manual for exact numbers.

Reattaching the Lower Legs

  1. Align the lower legs with the upper stanchion and gently push them back into position. Ensure the lower legs are seated correctly without forcing them.
  2. Tighten the lower leg bolts using the 5mm Allen wrench. Ensure that they are torqued to the recommended specifications.

Reassembling the Fork

Sealing and Final Checks

  1. Install the fork seals using the fork seal press. This tool ensures a proper fit without damaging the seals during installation.
  2. Fill the lowers with fluid, ensuring both legs have the appropriate amount of oil. Use a syringe to avoid spills and ensure accurate measurements.

Installing the Fork Back into the Bike

  1. Install the fork back into the headset and reattach the stem bolts. Make sure the fork is properly aligned before tightening.
  2. Reinstall the brake caliper and ensure the brake system is functioning correctly before riding.

Troubleshooting Common Issues

Air Leaks

  • Cause: A worn air spring seal or incorrectly tightened top cap can lead to air loss.
  • Solution: Check the air spring seals for damage. Replace them if necessary. Ensure the top cap is tightened properly, but avoid over-tightening.

Rough or Sticking Fork

  • Cause: Dirty or improperly lubricated seals can cause stiction or a rough feel when riding.
  • Solution: Clean the seals and stanchions thoroughly. Apply suspension grease to all moving parts to reduce friction and improve performance.

Loss of Rebound or Compression Damping

  • Cause: A damaged damper or improper fluid levels can result in poor rebound or compression damping performance.
  • Solution: Rebuild or replace the damper. Ensure fluid levels are correct for the specific model. If the problem persists, inspect the damper’s internal components for damage.

Customization and Optimization

Adjusting Air Pressure

  • To fine-tune the suspension, adjust the air pressure in the air spring. Experiment with small adjustments to find the ideal setup for your riding style. The Float 38 Factory offers a wide range of adjustability, so don’t hesitate to experiment for a smoother ride.

Fine-Tuning Compression and Rebound Settings

  • Compression: Adjust the compression settings to control the fork’s response to rough terrain. A higher compression setting will provide better support on aggressive terrain, while a softer setting is ideal for smoother trails.
  • Rebound: Adjust the rebound to control the speed at which the fork returns to its extended position after compression. Too fast a rebound can lead to instability, while too slow can make the fork feel sluggish.

Comparison with Similar Models

When considering the Float 38 Factory Orange, it’s helpful to compare it with similar models, such as the Fox 36 or 40. The Float 38 offers superior stiffness and control, making it a preferred choice for riders who demand more aggressive handling. The main difference between the Float 38 and the 36 is the increased diameter and the stiffer design of the Float 38, which makes it more suited to aggressive riders. The Float 40, while offering slightly more travel and stiffness, may be overkill for some riders and is better suited for downhill enthusiasts.

Compatibility with Other Drivetrain Components

The Fox Float 38 Factory Orange is compatible with a wide range of modern drivetrain components. However, you should ensure that your frame is designed to accommodate a 38mm stanchion fork. In addition, consider your riding style when selecting components like brakes and wheels. For instance, pairing the Float 38 with a high-quality set of downhill or enduro wheels and brakes will ensure you get the most out of its performance capabilities.