How To Rebuild Fox 2.5" Coilover w/ DSC

Hey folks, here's a quick overview of how you can rebuild application specific fox 2.5" Coilovers with Dual Compression adjusters for the front end of a Toyota (this is either for a 4runner or tacoma not sure which) at home. I tried to do this in the simplest way possible with the least amount of shock specific tools to help out the DIYers tackle their first rebuild. This is a great way to get more familiar with your suspension and gain the confidence and experience needed to revalve your shocks at home.
Apologies for the quality, these videos are supposed to be in 4k but im gonna be honest, i dont really know what im doing.
Here's some links to the tools/products i used in this video, the amazon links are affiliate links and i do get a very very small portion of any purchases made when clicking through them.
Vice soft jaws: amzn.to/3wbCVQZ
Gloveworks HD Gloves: amzn.to/3CbMlzz
Super Lube Synthetic Grease: amzn.to/3dtXf9v
Shop Towels: amzn.to/3QRbRy2
Variable Pin spanner: amzn.to/3dxXUH5
Branick 7600 strut compressor: amzn.to/3QvC9X7
HD snap ring pliers: amzn.to/3K3oGU6
Powertanks shock inflators: powertank.com/collections/sho...
Reservoir Cap Removal Tool: www.schmidtyracing.com/Schmid...
Harbor freight pick sets: www.harborfreight.com/hand-to...
Shaft Seal Bullets: www.schmidtyracing.com/Shock-...
We also have shock/suspension tools on our site:
Shock Shaft soft jaw: www.wheeleveryweekend.com/col...
Fox No-Loss Nitrogen Gauge: www.wheeleveryweekend.com/col...
AGM Shock cap jaws: www.wheeleveryweekend.com/col...
You can get rebuild kits, snap rings, and bearings from our friends at: www.shockseals.com/
A few notes about shock rebuilds:
Many shocks have specs for ifp depth for the body/rod size/travel/resi length. When hydraulic fluid is heated it expands an average of 4% per 100 degrees F, 400 degrees of heat expansion over a 10" 2.5 cylinder will increase the volume to around 11.5" (not accounting for piston/rod displacement). If you don't want to pull the resi apart to set IFP depth you can use hydraulic pressure by quickly cycling the piston in, or out, to move the IFP. If that fails just use some long needle nose pliers but don't tell anyone i said to do that.
It's critical that you clean the shims before putting them back on. Imagine if you get a spec of dirt or abraded O-ring in between your shims and don't clean it off, even just half a thousandth (.0005") of an inch of crud in between each individual valve... That will produce preload of .003" and just that small amount of preload can have a substantial change in low speed damping force produced by the shock. This can critically alter your damping curve and take it from linear/progressive to digressive. This is also why you have to inspect the shims and replace any that are bent, warped, or otherwise damaged.
I was hoping to post the rebuild pdf along with this video but unfortunately no one is answering my emails, and i cant find mine in my shock drive. Ill be posting a video on rebuilding/revalving 7100s next, and this winter I've got some step by step revalving videos planned.
RTT security mounts/Shocks/Merch:
www.wheeleveryweekend.com/
Podcast:
wheeleveryweekend.buzzsprout....
Instagram:
/ wheeleveryweekend
Thanks for following along
00:00 Introduction
00:59 Shock Overview
02:17 Release Nitrogen Pressure
03:31 Remove Wiper Assembly
04:42 Main Seal/Rod Removal
06:35 Piston/Valving
08:43 Drain old Oil
09:25 Reservoir End Cap Removal
10:59 Reservoir IFP
12:31 DSC internal inspection
12:52 Shock Parts overview
16:18 Replacing Main Seals
24:42 Rod/Seal/Piston Re-assembly
28:15 IFP install
28:52 Oil/Bleeding
31:13 Inserting the piston/rod
34:33 Seal Assembly install
36:24 Reservoir End Cap
39:08 Pressurizing
40:42 Final Assembly
42:05 Final Thoughts
Get The Kids Aren't Alright by The Offspring here lickd.lnk.to/SF8ecMID!Wheel%2...
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Get this and other songs for your next KZbin video at lickd.co

[@chrismanley5656]

Fantastic video, super informative. I absolutely love that you just leave in the bits where you made an error, ‘yeah, fish this out of the bin.’ Bloody brilliant.

[@kafoxmechanic8922]

Hi sir I'm the Fox shocks technician from Philippines...love your vedios....

[@jurelle]

Thanks for sharing Ian! Some specialty tools and patience and it appears to be a relatively simple process. Also, enjoying the uploads! #FrontierComplete2023

[@WheelEveryWeekend]

The frontier has to be out of my life soon haha. I'm waiting on an adapter for the atlas before i final weld anything. As soon as it shows up im doing 20 hour days to get it off my plate.

[@rockmanagementoffroad9462]

Good stuff! I learned to do this a few years ago from a pretty lousy youtube video. It was pretty straightforward in the end but I was "shocked" by the lack of information available 😏.

[@WheelEveryWeekend]

It's really not rocket science, figuring out where each shock specs IFP depth is really the most annoying part. I'm hoping to post a bunch of these to enable the end users to pull their stuff apart if they want to.

[@Kiwigd]

Thanks for the clinic Ian.. much appreciated 🤙

[@WheelEveryWeekend]

Thanks for watching!

[@goldenratio5117]

Good info here I dig the video!! I purchased a used Tundra and it's got the fox 2.5 series.... I had a lot of loose bolts on the front end and clunking going on. Debating rebuilding or swapping and rebuilding. I think my lower Arms are bad but if I'm in that far I want to do the bushings on rack and pinion.

[@RAM5500CAMPERTHING]

Excellent work sir

[@WheelEveryWeekend]

Thanks man im trying!

[@krebel86]

I always loosen the seal head assembly before letting the gas out of the shock. It holds everything together. I’ve had the assembly spin and not come apart

[@antonelimacalinao229]

Excellent and detailed informative video! Fox truck shop here from the Philippines. Want to get that nitro valve gauge set

[@shirolee]

This is so awesome! But I think I'd rather just send you my shocks to rebuild seeing as you would do a much better job than I would!

[@thomasblais3612]

I would like to see your vacuum set up. Is it some you made or purchased?

[@BryanMartinez-ev8hc]

Can you make a video showing how you used the vacuum for the air bleeding?

[@Austin_Kait656]

i want to know about the vacuum you talk about! how it works and functions

[@LOYLSkipSh0t]

GREAT video thank you!!

[@WheelEveryWeekend]

Glad you liked it! Hopefully this is easier to go back and reference than it is to try and remember the quick shock class we did.

[@LOYLSkipSh0t]

@@WheelEveryWeekend yeah after rewatching, i picked up on somethings that i forgot since we did that. And also I dig the alternative you showed for bleeding air, super cool. Always nice to know the low tech options, very DIY friendly.

[@ebkbk9902]

I know this is a older video but ive been on the fence with either buying 2.5 king or fox front and rears. Im looking at both non adjustable models with the fox being 2600 and the kings being 3100+. Also the kings have a 6-12 month backorder! Im trying to build a budget minded prerunner and would like to do some spirited driving. I was told kings oil is good for 230° when foxs is good for 400° will the kings experience shock fade first?

[@jditts]

Fox has higher viscosity rated oil, higher temp rated oil. Higher tensile strength piston rods as well as Viton seals. They also have more seals/wipers vs King.

[@ebkbk9902]

@@jditts I ended up with the 2.5 fox kit with dsc i enjoy them so far alot!

[@sas86toy]

Your so awesome !!

[@WheelEveryWeekend]

I try, hopefully this is easy to follow and do without any specialty tools

[@bbreed1]

How would I know when I need to rebuild. I hear noise. That is why I am asking

[@liamcrawford2197]

What's the IFP depth set at for these fox factory 2.5s?

[@quinnjones1221]

How much is a rebuild per shock? Thanks

[@bbreed1]

Where r you located?.

[@jarrettcoffelt1868]

Anyone know how much oil I need to buy to do all 4 shocks