Remove all 3 body/frame screws.

Start to seperate the body uppers from the triggerframe. You may need to push on the board from inside the triggerframe to help it slide out. BE CAREFUL at this stage. Things can break.

Remove the front hose from the ASA 90*air fitting.

Remove the electronics and pneumatics from the upper body.

Slide inner body out from shell. Promptly discard shell.. Please re-cycle plastic! :)

Remvoe the clip holding the back air donut on.

Remove the back donut.

Sight down the length and make a mark (scratch, marksalot, etc) near the tail that aligns up with the bottom of the body. (inline with the other mounting holes on the bottom)

Lube the O-rings on the new Delrin air donut. (note- the rest of the pictures do not show lube-- our mistake!)

Install the new Delrin air donut. It can go on either way.

Slide on the tail access plug and rotate it (it shoud have about 22* of rotational "slop") to see if one of the 5 holes align up with the mark on the bottom of the body. If none do, remove the tail access plug and rotate it 1/6" turn and slide it back on. keep doing this until one of the 5 holes in the tail access plug line up with the mark on the bottom of the body. (note- ONE and ONLY ONE of the 5 holes will align up). Once you find this orientation, make a mark on the tail access plug to match the mark on the bottom of the body, so that if the tail access plug come off in the future, you can easily find the correct orientation.

Now, break loose the bolt chamber from the breach. These are the threads that will be used to allow the bolt to be removed out the back and re-attached again.

Parts laid out.

Slide the breach into the body from the front.

Slide the bolt assembly in from the tail.

Thread the bolt assembly into the breach.

 

--NEW UPDATES--

 

We have made some changes to the new 90* air fitting that replaces the stock Ion 90* air banjo bolt. there are currently two newer variations. One is a modified Ion banjo bolt that is cut down for clearance. Simply use this one in place of the stock Ion 90* banjo bolt-- It screws directly into the bottom of the body (the only hole that is threaded on the body).

The most recent version we have is a manfold that replaces the 90* air fitting. Here are some instructions of how it installs:

Remove your stock Ion 90* banjo bolt off the back short air hose. Use some Shocker/Ion lube on the air hose and press the new manifold onto the holse like this:

Slide everything down and make sure the new manifold fits neatly into the back pocket of the trigger frame.

Looking from the side, make sure the body of the manifold does not stick up above the triggerframe, and also make sure that the O-ring in the manifold does stick up past the trigger frame. It is intended to make a seal contact to the bottom of the body.

 

--The rest of these images depict the older 90* air fitting on the body, but the instructions still apply to the rest of installation.--

Everything attached and ready to go back together.

Install and leave the front two screws finger tight (remember there is front screw under the barrel that comes in from the top of the body!)

Use the 22* of rotational slop here to allow the back bolt to "find" its correct hole.

Tighten the back bolt.

Tighten the front two bolts. Make sure any wires and hoses are not pinched as you tighten all the bolts.

Done!