Larry posted on June 15, 2009 13:34
Bilstein 7100 Series Revalving instructions
By Larry Grubbs
(Always use Safety glasses while servicing shocks)
Tools required for disassembly and revalving:
- Chisel
- Hammer for chisel
- 2 slotted screwdrivers
- Bilstein Disassembly tool, or 2” PVC cut just longer than the length of the shock tube.
- Knife or thin screwdriver
- ½” Socket
- Locktite 271 “Red”
- Rubber mallet
1) Release gas pressure from Shrader valve on shock tube or the remote reservoir end cap.
2) Carefully remove gold dust seal from shock tube with a chisel.
3) Depress Rod Guide into tube and remove outer snap ring. Use a knife or some other sharp object to pry up the edge of the snap ring. Use caution, the snap ring can fly across the room.
4) Utilizing the 46mm Disassembly Tool (part # 193434 from Bilstein), and 2 slotted screwdrivers, remove rod guide from shock tube. This shouldn’t require a lot of force. (Use the Disassembly tool for leverage, fit the slotted screwdrivers into the outer rod guide groove and pop guide up.) Alternatively you can use 2” PVC pipe cut long enough to pry from so as not to pry with the body of the shock.
5) Remove the inner snap ring in similar fashion to step 3.
6) Slide out piston rod and piston from the shock tube. Drain oil as needed.
7) Cover shock body to prevent contamination and place aside for now.
8) Clamp the shaft of the piston rod and remove the nylock nut from piston rod. Wrap several rags around shaft and place in vise taking care not to overtighten the vise.
9) Remove the valve stack. Compression side is toward the shaft. Rebound side is toward the Nylock nut. The piston has an oval shaped marking on the rebound side. This marking should be facing toward nut.
10) Replace old valve stack with new valve stack. Ensure that piston with oval shaped marking is facing the Nylock nut.
11) Install Nylock nut using 271 “Red” Locktite. Torque to 7 lbs.
12) Reassembly is reverse of disassembly.
13) Fill with Nitrogen gas to 180-220 PSI. Can fill to 300 PSI if needed.