About a month ago my buddy and I changed the fork tubes out on my 07 Bob. I replaced the stock tubes with some show chrome tubes I got at Custom Cycle Engineering. I had already changed the sliders to chrome ones about two months previously and decided the chrome forks would look better than the stock brushed aluminum look.

We already had a good idea of how to do the fork change because we both did the slider change without too much trouble. I have a manual and my buddy is a parts and service manager at a local Ford dealership so he can read a manual and is mechanically inclined. The hardest part was trying to figure out how much oil to replace the oil we removed. After a call or two and draining the second tube and catching all the fluid and measuring it we figured it out.

THE QUESTION.....After we replaced the tubes/seals/oil/etc. One of the tubes leaked! And then about a week later the other started to leak! What do I need to re-check? Something I missed? I have run this through my mind a hundred times and cannot think of a reason.

I called Custom Cycle Engineering and talked to Rick and asked him if they had had any problems with the 49 mm tubes and he said not that he knew of. He offered to replace them if they don't stop leaking but I hate to replace them if it is my mistake.

ADVICE??????????????

 

being an aircraft Hyd Mechanic I am assuming that at some point sliding the tubes into the sliders you cut a seal. this happens all the time when we are re assembling UH-60 landing gear struts which is why we have to pressure test them for 24 hours before reinstalling. This can sometimes be prevented by taking some 400 grit wet dry and wet sanding any burs or sharp edges on the bottom of the tubes. Also use plenty of lube while assembling, sliding them in dry will definatly cut the seals. Hope this helps.

 

Yeah, I'd bet on the seals as well. What tool did you use to re-install them?

 

Yeah if you dont get the seals just right your done...

 

sounds like the seals where not put in right

 

I'm going to go out on a limb and translate what these guys said. What they're saying is...re-check your seals. lol

 

We used the 2" pvc pipe to install the seals but we didn't "lube" the forks first. I guess that could be the problem. Next open weekend we'll tear them back down and replace the seals.

 

You never did say where they're leaking from. Like everyone else I'd guess it's the seals.

Did you drive the bushing in by itself first, then install the seal after that? Or both at the same time? Always drive the bushing in seperate from the seal.

Did you drive the bushing down far enough? Was the seal easy to drive down far enough to get the retaining ring installed.

Did you take extra care while starting the seal over the end of the tube (like use sandwich bag over the tube to protect the seal while installing)?

Did you lube the seal, ID and OD? How 'bout the tube prior to sliding the seal down into position?

Did the tool you used have the proper relief to prevent damage to the seal's lip and to drive the seal on the 'meaty' parts of the seal?

Is there enough air in the shock? Too much fluid will result in blowing seals.

Show chrome tubes will not hold up as well as hard chrome tubes, but new they should be just fine. If you have a caliper or micrometer you could compare the diameter of the old and new tubes.

 

You never did say where they're leaking from. Like everyone else I'd guess it's the seals.

"It is just a residue which builds up after a while and then starts to drip."

Did you drive the bushing in by itself first, then install the seal after that? Or both at the same time? Always drive the bushing in seperate from the seal.

"bushing first and then seal afterwords"

Did you drive the bushing down far enough? Was the seal easy to drive down far enough to get the retaining ring installed.

"yes"

Did you take extra care while starting the seal over the end of the tube (like use sandwich bag over the tube to protect the seal while installing)?

"no"

Did you lube the seal, ID and OD? How 'bout the tube prior to sliding the seal down into position?

"no"

Did the tool you used have the proper relief to prevent damage to the seal's lip and to drive the seal on the 'meaty' parts of the seal?

"yes"

Is there enough air in the shock? Too much fluid will result in blowing seals.

"We checked the amount of fluid and double checked to make sure it was the correct amount"

Show chrome tubes will not hold up as well as hard chrome tubes, but new they should be just fine. If you have a caliper or micrometer you could compare the diameter of the old and new tubes.
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