Penske Racing Shocks 7800 Series - Manual (Page 4)

4
Disassembly / Assembly Instructions
Disassembly Instructions
1. Depressurize the shock.
2. Clamp the body cap eyelet in the vise with the shaft eyelet pointing up.
3. Unscrew the shaft bearing assembly from the shock body and remove the shaft
assembly using a Penske bearing wrench (Part number TL-78W)
4. Drain the oil, when needed. Please dispose of properly.
5. Clamp the shaft eyelet in the vise with the piston pointing up.
6. Remove the 1/2" ring nut to access valving.
Assembly Instructions
1. Install shaft bearing. Be sure to grease seals and o-rings to prevent any damage.
2. Reinstall eyelet. Use Red Loctite on eyelet threads and tighten securely.
3. Reassemble the shaft, be sure that the piston is properly positioned. With the
shaft still in the vise, the compression valve stack is on the bottom of the piston
and the rebound on the top. Bleed holes are on the rebound side (facing
K)
4. Torque 1/2" ring nut to 150 in•lbs.
5. Pressurize body to 50 psi. Fill body with oil*, stopping at lower threads.
*Penske Suspension Fluid (Silkolene Pro RSF 2.5 wt.) is recommended. Use of alternate
fluids may have an adverse effect on the damper's internal sealing components.
6. Insert shaft assembly with piston band into body. Move piston assembly up and down
slowly (1"-2" strokes) to extract all air. DO NOT pull piston assembly out of the oil at
this time.
NOTE: this step is very important; take your time, repeat as needed. When all air
is bled out, slide the shaft bearing down and screw it into the body until it is snug.
Let the pressure out of the shock and finish tightening the bearing.
(DO NOT OVER TIGHTEN).
7. With the shaft fully extended, charge shock with desired pressure.
(DO NOT EXCEED 150 PSI)
Replacing the Shaft Bearing Seals / Eyelet
1. Remove eyelet from shaft using a shaft clamp (Part number TL-78SC)
2. ONLY REMOVE SHAFT BEARING OVER EYELET THREADS.
3. Replace seals and wiper if needed.
Continue following steps 1 through 7 in the Assembly instructions above.
Specifications
Ring nut, 150 in•lbs
Eyelet to Shaft, (Red Loctite)
Shaft Eyelet
Shaft Bearing
Body Cap Eyelet
Nitrogen Pressure Valve