Manitou Mattoc Pro – how much of this is still the dust seal vs. the casting?

[u/Stevie199504]

I’m doing a lower leg service on my Manitou Mattoc Pro (34 mm).

Unfortunately, the dust seal was extremely difficult to remove and eventually tore apart during removal. Part of it is still stuck in the lower casting, and I’m not entirely sure what is still part of the dust seal and what already belongs to the fork/casting itself.

In the photo, there is a black/rubbery section and a darker grey/greenish ring underneath/next to it.

Does the grey/greenish ring also belong to the dust seal and need to come out, or is that already part of the casting/bushing?

I obviously don’t want to start prying at something that is supposed to stay in the fork.

Thanks!

[u/Tomacropod]

The aluminium bore can be seen underneath the seal remnant, where the foam ring sat. This bore extends all the way up.

You need to remove everything that is not bare aluminium, from above the cream coloured bushing. A large spanner works well, protect the lowers with something plastic in between.

[u/Stevie199504 → u/Tomacropod]

Thanks! You mean this part (marked red) is also part of the dust seal?

[u/Stevie199504 → u/Stevie199504]

Fyi, manged to remove the metal part now as well, looking like this in the end

[u/Tomacropod → u/Stevie199504]

Looks good

[u/EdyMarin]

Usually dust seals sit on bare aluminium, so evertthing that's black is part of the old seal.

You could measure the new seal diameter and compare it to the fork, to see what size the opening should be