Gen 2 SCAB makeover…totally not ripping off Geoff’s 2.5 build!

[Nex]

I have a hard time getting enough leverage with my 1" too.

 

[91Eunos]

Another tiny step forward… Got the front bumper and stock intercooler removed, as well as the transmission cooler lines, and a few other small bits so I can finish cleaning and prepping the frame for the rebuilt motor install:



…clearly some transmission fluid remaining in those lines, LoL.

Since I gotta clean up the mess anyway, I’ll try to get to the front differential cover this evening too; depends on how long my afternoon errands take to complete. I gotta keep moving on this…the piles of parts is becoming worrisome!

 

[91Eunos]

Swapping out the front diff cover was a bit more involved than anticipated. I honestly thought it was gonna be a 1/2 hour or less project since I had easy access to all the bolts with the bumper and intercooler out of the way.

LoL

Draining is always a messy pain in the ass with a cover that doesn’t have a drain:



But what I didn’t plan on was having to partially drop the power steering rack to even get the stock cover off. And in their infinite wisdom, some random Ford engineer decided that one of the bolts should have a 21mm head, and the other a 22mm. And put in with well over 150 ft/lb of torque…good God.


The diff itself only required a little bit of cleanup though…pretty clean fluid too despite the miles. I’ve never changed the front diff fluid in 115K miles!



Note: You’ll have to push the rack as far back and upwards as you can get it to go on the RH side…and drop the LH side as low as you can as as well, to get it as far forward as possible to clear the diff cover:



Spicer cover is a tight fit, but no clearance issues:



Also, while the lower fill plug is easily accessible from the bottom with a regular 3/8” square drive, if you want to use the top plug like I did, you’ll need one of these 3/8” to a 9/16” bolt head adapters…or a very thin-headed 3/8” ratchet I suppose:



Thought I was gonna have to break out the fluid transfer pump and a hose, but a small funnel just fit into that top fill hole. Mine took just over 2 quarts to fill.



Ops checked by rolling it back and forth a few times and checked for leaks several times…seems gtg, but will check it again mañana.



More to follow…