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have you contacted the manufacturer or atleast the distributer...they may have some recommendations for you also this way they are aware of the problem and will be more apt to suit your needs if you are unhappy after a few attempts at solving the issue. just some food for thought -Chez
BTW: I rebuild motorcycle forks at work all the time and I use a 3/8 cordless impact to take them apart as well as tighten them back up and as long as your carefull around the dampening rod you will have no ill affects. just as long as you dont sit there and spin the shaft once the nut is tight. just give it a few short bursts about a second long...that is if the person you talk to says to try and tighten the upper nut...
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