I usually pull the whole tube assembly out of the trees, (remove axle, wheel, fender, caliper etc.
Drain the fluid from the drain screws on the slider.
Then pop the metal cap off the slider with a punch and hammer, (there's a little grove on the slider).
Pop the dust seal out with a flat screwdriver.
Pull the clip out using a thin screwdriver.
Then hold the fork tube assembly upright with the end of the slider on the shop floor, (put a rag under it so it doesn't get scratched). Compress the fork a few times and the seal will usually pop out of the slider, (I usually put my hand on the top and hunch over it pushing down with my chest).
Clean everything because fluid usually gets everywhere.
Slide a new seal down into the slider as far as you can by hand and make sure it's started in the hole properly.
Take a piece of PVC pipe that has a inner diameter larger than the fork tube diameter and longer than the fork tube, (I took a little ruler to home depot and measured various pipes until I found one that'll fit over the tube, 1.6" if I recall). 1 1/2" Schedule 40 PVC about 30 inches long should suffice.
Slide the PVC over the tube and against the seal, hit the end with a mallet until you can see the groove for the clip above the seal.
Snap the clip back in place. Make sure it's seated in the groove.
Slide the dust seal in place and use the pvc pipe to seat it, (usually a couple whacks on the PVC with your hand will do it.
Slide the metal cap back in place, use the PVC pipe to seat it down, (place a rag between the cap and the end of the PVC if you don't want to scratch the cap.
Reassemble the forks and you're done.
Last edited by punkrod; 06-14-2012 at 5:41 PM.