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    Default Stuck 39mm Fork Bushings.

    Hi guys,

    I was working on replacing my fork seals on my 2001 FXDX this weekend. When I went to take the lowers apart from the tubes the slide hammer method wasn't enough to pull the bushings out. I Cant get them to separate. I have never had this much trouble rebuilding a front end before. I have tried heat but I didn't get it that hot. Has anyone had this problem before? I think what is happening is the bushing on the tube is getting jammed inside of the bushing in the leg making it bind therefore not letting me pull them apart. Any help is much appreciated as I am out of ideas.. I thought about making a cap with a valve stem on it and try and use air pressure to push them apart but I don't know if this is the best idea or if it would even work..

    https://www.reddit.com/r/Harley/comm...iders_help_me/

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    Looked at a parts diagram for you FXDX?

    Click image for larger version. 

Name:	HD01FXD032.jpg 
Views:	7 
Size:	63.1 KB 
ID:	90039

    http://partsfinder.onlinemicrofiche....TEERING%20STEM

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    Yes everything was assembled correctly. Part #16 (Slide Bushing) seems to be getting wedged in part #15 (Bushing Upper) when I try and slide them apart.

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    Just to be sure....did you remove the nut/bolt at the base of lower? Can the tubes rotate inside the bushings?

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    Quote Originally Posted by BlackCloudSalvage View Post
    Just to be sure....did you remove the nut/bolt at the base of lower? Can the tubes rotate inside the bushings?
    That's what I was wondering..... Has he got the tube out and trying to get the bushing out now? I would like to see pics of where he is at.... Many times describing something doesn't come through like it looks....

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    Assuming the damper bolt is out
    How else would the two bushings get close enough to bind?

    I've has corrosion hang up the upper bushings a few times. And yes, then they tend to jam together while trying "slide hammer" the leg off the tube.

    Make sure you dig out all remnants of the seal clip.
    Try to pry out the seal if you can. Carefully.
    get that steel washer(s) out too.
    Then lots of penetrating oil and heat cycles.
    I get it hot enough to boil the oil but not flash burn it.
    Hen it gets stuck hammer the lag back on and start over (dead blow)

    The pattern is
    Oil
    Heat
    Slide
    Beat
    Repeat
    Eventually you'll get it.

    The hardest part is being patient enough to not damage the leg or the tube while persuading them apart.

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    Quote Originally Posted by Sky View Post
    Assuming the damper bolt is out
    How else would the two bushings get close enough to bind?

    I've has corrosion hang up the upper bushings a few times. And yes, then they tend to jam together while trying "slide hammer" the leg off the tube.

    Make sure you dig out all remnants of the seal clip.
    Try to pry out the seal if you can. Carefully.
    get that steel washer(s) out too.
    Then lots of penetrating oil and heat cycles.
    I get it hot enough to boil the oil but not flash burn it.
    Hen it gets stuck hammer the lag back on and start over (dead blow)

    The pattern is
    Oil
    Heat
    Slide
    Beat
    Repeat
    Eventually you'll get it.

    The hardest part is being patient enough to not damage the leg or the tube while persuading them apart.
    Damper bolt is out. This sounds like the thing to do I am going to try it out. Thanks for the help!

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    Quote Originally Posted by BlackCloudSalvage View Post
    Just to be sure....did you remove the nut/bolt at the base of lower? Can the tubes rotate inside the bushings?
    Yes the bolt that holds the dampener assembly is removed and the dampener assembly is out as well. The tubes rotate and slide fine.

    Tattooo - I can't separate the legs from the tubes. I can try and get pictures.

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    Quote Originally Posted by JBOSAK View Post
    Tattooo - I can't separate the legs from the tubes. I can try and get pictures.
    That's what I thought....

    Is the spring still in the tube?

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    Quote Originally Posted by Tattooo View Post
    That's what I thought....

    Is the spring still in the tube?
    No the spring comes out with the damping rod. I think I am going to try what Sky recommended. I did get the old seal out and then I could see the bushing was slowing working its way out. It's moved about a 1/8. I have done plenty of fork rebuilds but I have never seen this happen this bad before. Sometimes they don't want to come apart but I usually can get them.

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    Quote Originally Posted by JBOSAK View Post
    No the spring comes out with the damping rod. I think I am going to try what Sky recommended. I did get the old seal out and then I could see the bushing was slowing working its way out. It's moved about a 1/8. I have done plenty of fork rebuilds but I have never seen this happen this bad before. Sometimes they don't want to come apart but I usually can get them.
    I've never had any problems getting them apart..... I'm curious what you find to be the problem...

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