Disassembly of King reservoir

Hello,

My reservoir of my king bypass shock is leaking at the hose cap. Now I think that this cap is threaded instead of pushed in and hold by the snap ring.
My issue is now, that I don't know how to remove/ unscrew the cap because it doesn't not have any holes or what's soever to attach a tool to.

Does anyone have an idea on how I can remove this cap?

I already thought about drilling two holes into it for the two pin wrench.

Any help is greatly appreciated... thanks

 

https://www.google.com/search?q=how...bile&ie=UTF-8#scso=_74UMXLvCEaua0gK32hA26:333

https://www.google.com/search?q=how...hq1QKHU_GCKoQrQIoBDAAegQIBhAJ&biw=360&bih=616

 

Here is a picture of the reservoir

 

Thank you...But I already rebuild 4 of my shocks, which is actually quite simple once you get the hang of it.

I was able to fully disassemble the reservoirs of the Coilovers (which have the push down caps) but unfortunately not the ones from the Bypass, because of this I think these are threaded or worse heat pressed.

 

No problem, I was hoping there was a video of what you were asking about or a thread in there that goes over the process.

 

Have you tried contacting King? That looks just like the reservoir on my coilovers. That cap should start to suck in if you depressurize the shock, compress it, and then pull the shaft out. There should be a snap ring once it pulls in a bit.

 

Email King tomorrow. They usually get back to me in a day. They have had no issue giving tech help over email or phone.

 

That has a snap ring. You need to let out the nitrogen in order to push the cap in a little and expose the snap ring.

The is the oil side though so be prepared for a mess and you’ll basically need a full rebuild to reassemble.

 

I already did the rebuild on the shocks a few weeks ago and I tried to remove this cap as well but it did not move at all even so i used a lot of force and therefore I think it must be threaded.
The reservoirs of the coilovers did not make any problems to fully disassemble tho.

Guess I have to call King tomorrow

 

Yeah, call King and see what they say.

That’s not a thread in style but who am I. Sometimes the caps get filled with dirt and debris and kind of seize together.

Keep us posted!

 

Aluminum cap inside a stainless steel tube = pressure + chemical bonding:

• Aluminum oxide creates additional volume inside the tube
• Aluminum and steel create a galvanic pair, with electrolytic reaction between them

Thus, manufacturer's recommended maintenance intervals.

 

Good point but I think the resis themselves are alumnium on the newer style. Can anyone confirm?

 

Resi looks threaded in the diagram; wall thickness is apparently > the bypass tube, so you may be correct:

 

You have a standard prerun resi, depressurize and after you get the IFP and oil out tap the end cap in or resi toward the hose to expose the C clip to remove it. The hose looks like NPT and those rarely fail if installed correctly.

The exploded picture posted is a race series resi that the end caps thread into the resi and NOT applicable with what you have.

 

Yep no threads at all, push harder lol

 

Thanks guys for the help.
I was finally able to take of the cap. Like the most of you already said it was the "push down" cap. Had to use the BFH method to get it finally loos.
In the picture below you can see why the reservoir was leaking, but I honestly don't know how the dent got there.

Anyway I ended up flipping the sides of the reservoir because leaking nitrogen is easier to handle than leaking oil.

 

You need to hone it out but that can be difficult depending on how deep. Other option is to replace the resi.

Any other thoughts?

 

Yes, I already worked on it with scotch bride and polish. You can feel the dent slightly but I hope the new seal will help it.

Otherwise will check the pressure in two weeks again...good tho that I bought/build a nitrogen refill kit. This already repaid itself.

 

I just leave the picture here to show the difference between old and fresh suspension oil. Unfortunately I cant say how many miles were already driven with it, because I bought the truck this year and don't exactly know when the previous owner installed the shocks