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Message: [QUOTE="Bud-Man, post: 125064, member: 20830"] The 1/4" or so of play is normal for that piece. During the reassembly process for the inner chamber, the slide bushing assembly will be forced upwards giving the spring a certain amount of preload. I don't think that is what is causing the noise you are hearing. It sound as if the fork may not have been re-assembled correctly. Do you have an owners manual for the bike? If so, I would double check the assembly order on all the components. Unfortunately, there are a number of possible situations that could be occuring if the fork isn't put together correctly and it is very hard to guess at it accurately. Was the fork making this noise before you dis-assembled it? [/QUOTE]