Can grease really block a transfer port? I know its an easy answer but seriously – a blob of grease holding back a pressure difference of 50PSI between the +ve and -ve chambers… I reckon there is something else at play.
Probably differing levels of vacuum in the lowers which essentially adds to the effect of the negative air spring. This is going to effect the plushness of the fork and how low it sits in the travel. After dropping the lowers off to service the air spring this air pressure in the lowers will be different when you put it back together – perhaps giving rise to the illusion that servicing the air spring made a difference.
Just my theory – could be rubbish – but i would like to see an experiment set up where a blob of grease tries to hold back 50PSI