These are the things you'll need for a complete overhaul of your Shocker with NDZ bolt: assorted allen wrenches (0.05", 1/8", 1/16", 5/64", 3/16", 5/32", 3/8"), Dow/Corning 33 Shocker lube, dowel rod (3/8" works good), clensing alcohol, 1/8" socket or pliers if your solenoid uses the lock screws (pre-3900 serial numbers only).
Disassembly:
Start by removing the four parts of the firing assembly out the rear of the body. Do this by removing the bolt guide first, using a 3/16" allen wrench.
Once you unscrew it to the point where the threads disengage, remove it by pulling straight out the back of the body. You can then insert a wooden dowel or similar tool into the bolt face to push the remaining parts out the back of the body. The fire chamber and bolt sleeve will all come out when you push on the bolt. Once you get the bolt sleeve out, you may have to pull on the back of the bolt if your tool is not long enough.
To get the bolt out of the fire chamber, you must remove the front cap of the chamber. Simply pull it off.
You must now remove the bolt's front o-ring in order to remove it from the chamber. A dental pick works good, however this ring is on there very tight so be warned.
Once the front bolt o-ring is off, you can pull the bolt out the rear of the fire chamber.
Maintenance:
Start by cleaning off all the grease from the o-rings on the firing assembly's four parts. Simply take your cloth and wipe old grease from the o-rings. In the below diagram, the outside o-rings are colored tan, whereas the inner o-rings are colored blue.
Below is my "quick method" for applying a new coat of grease onto the o-rings. This is my method that I've come to use after servicing literary hundreds of Shocker firing assemblies since 2004...I believe it to be easiest and fastest.
Step 1. Slide the fire chamber onto the bolt, making sure it's not backwards (the open end faces forward). Then slide the 15/90 bolt o-ring around the front of the bolt and push it down into its groove inside the fire chamber. Once it's seated in the groove, reinstall the fire chamber front piece onto the bolt and snap it into position. Be careful that you don't pinch the 20/70 o-ring in the fire chamber.
Step 2. Now that the fire chamber is installed on the bolt, you will grease it so it will apply lube to the opposing o-rings. Apply a new coat of grease all around the bolt sail o-ring, then grease the following parts of the bolt (labeled in the following diagram). space behind the bolt o-ring, space in front of the fire chamber, and space between the bolt o-ring and fire chamber. Again, use this diagram:
Step 3. Slide the bolt sleeve onto the rear of the bolt, with the flared end facing backward (use the provided diagram). Now it's time to re-grease all seven outside o-rings on the assembly before installing it in the body, as shown in the following diagram:
Step 4. Install the two side o-rings (16/70's) onto the side of the fire chamber. Apply an amount of grease to your fingertips and smear it around the o-rings so they are well lubricated.
Step 5. Push the assembly back into the Shocker body, fire chamber in front / bolt sleeve in back. Once you have the front of the fire chamber inside the Shocker body, look at the Shocker symbols in the body to align the side o-rings of the fire chamber. Gently push the assembly into the Shocker body, being careful that neither of the side o-rings get pinched (if they begin to pinch, pull the assembly out a little bit, hold the o-rings down with your finger, and try again).
Step 6. Re-grease the two front o-rings on the bolt guide (see the following diagram) and push it into the body. Once it's in, screw it down using your 3/16" allen wrench.
A frequent question I receive is how much grease should be applied to the bolt and components. To answer, I will demonstrate with this picture of an HE bolt. This would be step 2 in the above paragraphs.
A "good" amount of grease would completely fill the o-ring groove, with some on either side of the ring, as well as on top of it. Markers are more difficult to "overgrease" than people realize, but you should still be wary not to slop too much grease on there.
The firing assembly is now cleaned and ready to use. You can now refer to the Related Links section for regulator, solenoid, or infrequent maintenance if necessary.
O-ring Diagrams:
Note, bumpers not shown.
Related Links:
· Solenoid maintenance
· Regulator maintenance
· Infrequent parts maintenance
· Firing assembly details
· Troubleshooting Leaking/Shooting