Stuck Fork Seals - help plz!

Energy One
JWScarab

JWScarab

Active Member
I have the tubes off the trees. Upper cap off and spacer/spring out. Lower 6mm fastener out. Dust caps off, and retainer clips removed above seals.

Ive tried the pounding method till blue in the face. WD40 sitting in there. Hair dryer heat (Im affraid to use more heat to ruin lowers).

BOTH are stuck!!!

Now, I did this job last year and the seals came out no problem with a few pulls. This time - nothing works!!

Any ideas???? :oldconfused:

Thanks!!!
 
KaptinAmerika

KaptinAmerika

Guru
You need a seal pulling tool then:
Seal Puller
Most of the time I do the same thing. Just bang the tube a few times and out they pop but every so often you get a bastard seal.
Just be careful and work your way evenly around the seal until it pops out.
 
JWScarab

JWScarab

Active Member
So this seal puller will fit between the o.d. of the tubes and the i.d. of the lower - then bite into the seal and pull it up? It seems too big of a head to fit in there - but I know you know what your doing Kaptin!

Let me know if I understand correct - and if so, I'll order one! Thanks again!!
 
JWScarab

JWScarab

Active Member
Oh wait a sec - does the head of that puller rotate??? If so - I can see that doing the trick!!

Thanks very much Curtis!
 
JWScarab

JWScarab

Active Member
I just looked again - the gap between the tubes and the outer lowers is narrow, and the seal is in there maybe 1" deep. I can see the puller working great if the tubes were removed, but maybe it will fit in that small area. Maybe I can bend the tool to a radius to fit the gap.

I also read somewhere that if I put the 6mm screw back in the bottom, then extend the tubes a little bit and fill them with completely full with oil, then put the cap on the top. Then compress the fork assembly - like between your truck bumper and a tree (protected of course) that the seal will pop out. Sounds like a trick, but dangerous!!
 
JWScarab

JWScarab

Active Member
Well I slept on it and I think I realized what Curtis was saying with the seal puller. Boy do I feel dumb! You just put "one point" of the tool down between the tubes and into the seal groove and try to dig it up a little at a time. Im going to stop by sears tonight to see if I can get a puller.

I'll keep you posted on the results. Funny thing is last time around they popped out no issues - this time both are stuck. Oh well. I'll post back soon. Thanks all!!
 
KaptinAmerika

KaptinAmerika

Guru
The seal is only in about a 1/2 inch
The tool looks clucnky but the pointed tip fits in under the lip of the seal.
I had to manipulate mine a bit to work for me.
Its a little awkward and destroys the seal but it works.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
JWScarab said:
I just looked again - the gap between the tubes and the outer lowers is narrow, and the seal is in there maybe 1" deep. I can see the puller working great if the tubes were removed, but maybe it will fit in that small area. Maybe I can bend the tool to a radius to fit the gap.

I also read somewhere that if I put the 6mm screw back in the bottom, then extend the tubes a little bit and fill them with completely full with oil, then put the cap on the top. Then compress the fork assembly - like between your truck bumper and a tree (protected of course) that the seal will pop out. Sounds like a trick, but dangerous!!
Click to expand...
Why are your seals in 1"? That's not right should be 1/2" like Curtis says.

Did you get a buddy to hold one end and you hold the other? Should slide in and out pretty freely.

And just stupid question...you removed the retaining clip, right? Haha

I would definitely not do that tree/truck deal haha. I doubt you make it out without needing new tubes. However if you do video it so we can watch!



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Last edited:
Th3InfamousI

Th3InfamousI

Administrator
Staff member
I'm thinking about this again I'm guessing it's sticking on the copper bushings.

What If you take a sharp knife and cut the seal between the outside and inside lip In a circle? Like an exacto blade so you can be careful not to damage the tube. Use painters tape on the tube to help protect it.

Edited:

I'm thinking cutting along the red line I drew stay away from the inside lip there is a small metal spring retainer on both sides.




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Last edited:
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Here is my second idea!

Bring water to a boil and pour into the top of the seal house soaking it for a minute. Keep pouring water on it for a minute to heat it up. If there was an easier way I would say stick the whole leg in but it's kinda big so you might just have to pour it on do it on the grass

Once it's warmed up it should soften the seal to pull it apart (maybe)

Haven't tried either of these options just thinking outside the box

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chubs

chubs

Guru
JWScarab said:
I just looked again - the gap between the tubes and the outer lowers is narrow, and the seal is in there maybe 1" deep. I can see the puller working great if the tubes were removed, but maybe it will fit in that small area. Maybe I can bend the tool to a radius to fit the gap.

I also read somewhere that if I put the 6mm screw back in the bottom, then extend the tubes a little bit and fill them with completely full with oil, then put the cap on the top. Then compress the fork assembly - like between your truck bumper and a tree (protected of course) that the seal will pop out. Sounds like a trick, but dangerous!!
Click to expand...
Oh yeah, the old truck and tree trick! :job: Here, I'll hold yer beer! GO FOR IT!!:oldhardlaugh::oldhardlaugh:( :oldnono::panic::nonod:)
 
JWScarab

JWScarab

Active Member
Guys - Im F-ed. I hate to admit it but I am. Yes I do have the lower 6mm bolts out and I also have the retainer clip out. I used the seal puller tool and now have both seals out and the large flat washer is out. The tool worked great, but I managed to put some nicks on the ID of the lowers. Also nicks on the groove where the dust cap o-ring sits. So I'm not sure I can file those nicks out. Secondly I also nicked up one tube pretty good. F**k!!! So I need new tubes - and "possibly" new lowers.

It gets worse. The seals were NOT the problem. the problem is the BUSHINGS. They are stuck in there solid. I still slide hammer motion the tubes like hell (and Im a larger guy) and no luck. Every time I do the they "stick" fully extended. In order to free them I have to hold the upper tube and SLAM the assembly on to the bench.

What is going on is the bushings are binding up and sticking to each other when I do the slide hammer thing. Then I have to beat them to get them to unstick. I do this over and over and the upper bushing will NOT come out.

I think the "press fit" of the upper bushing into the lower is so tight they are stuck. If I dont get the bushings out, I cant get the tubes out. Then I cant get in there to clean up the nicks. The parts are all pretty f-ed up.

I guess to say Im frustrated and pissed is an understatement!! UUUUGGGGGG

Ive got an email to bigdogpartsking for a price on new lowers. I may just buy new shit - but I dont want to spend the $$.
 
JWScarab

JWScarab

Active Member
Your not kidding!!! I like my shit "correct" but I'm pissed now. I'm possibly going to sell the bike and could have easily just told the new buyer it had a fork seal leak. But I wanted to fix it right so the buyer had a bike with no issues. This is what I get for trying to do the right thing. Oh well.
 
Th3InfamousI

Th3InfamousI

Administrator
Staff member
Can we get a picture?

My mind is currently blown how the seal is out but the tube is still in there? Those bushings Are on the tube itself which is a good bit smaller than the lowers. I'm having trouble understanding what they would be binding on if the seal is now out? I assumed before the bushings were binding on the seal causing problems but that can no longer be the case.

Here's the bushings on the tube and you can see the seal at the top.


Now here is the lower. The difference between the tube and the slider is the width of the seal. I'm so confused! Haha



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