Help! RockShox XC32 Top Cap Stuck

iLukeKendall

I'm currently in the process of trying to change the spring in my RockShox XC32 fork. So far I've pulled the lowers, but I now have a major problem.

The top cap (which is STUPIDLY made from plastic) requires a 24mm hex socket wrench to undo. When I've tried to undo it, the hex wrench just slipped and rounded off the plastic head, meaning I now have no way of getting purchase on the cap to undo it.

Does anyone have ANY suggestions, please?! I'm replacing the cap with the new spring, but I need to get the old one out first

oxocube1

24mm cone spanner maybe the best option.

iLukeKendall

Thanks oxocube, however unfortunately I don't have one that size. I tried using an adjustable wrench/spanner, however the cap edges are so thin that it just flexes when I try and undo it. I'm now at a point where the edges are almost totally round, so I really don't know what to do!

The Rookie

Cut it out and buy a new one....

iLukeKendall

I thought about doing that, but how would I go about it without damaging the threads on the inside of the crown/stanchion? I already have a replacment cap to go on that came with the spring.

peter413

If you're replacing it anyway try some mole grips. It'll wreck it but that doesn't matter.

Horton

A lot of sockets are chamfered for the first mm or so which means if the nut/bolt/top cap you are trying to undo then hardly any of the hex bit of the wrench is in contact so makes it easy to do what you've done... I've ground one down to remove the chamfer to avoid this issue.

As far as removing the one that's in there - def try mole grips but if that fails, can you cut a notch in each side directly opposite each other so you can use something like a file to undo it - like a t-wrench?

ravey1981

Cut a small notch and use a flat blade screwdriver as a drift to tap it round until it loosens.