Pretty straightforward. But unlike some of the posted videos (e.g. CJ Pony), using the lower hole to fill is about 3.5 quarts so had to run down and buy a forth to finish up. Also, you will have to reuse one of the hanger bolts off the org diff case for a brake line bracket near the top.
Now while spare out, I power washed it. Going to paint any rusted areas with black Rust-Oleum and then hit underside with Amsoil HDMP.
Some more info in this Gen 1 thread.
http://www.fordraptorforum.com/f5/ford-performance-diff-cover-58042/
- Drop the spare. Enough room under there to almost sit up. You might be able to do it on a lift without dropping spare, but it would be a pain. Picture of original diff case in Pic 1.
- It was kinda dirty for only 4k miles. Pic 2.
- Covered the gears to keep crap from falling into gears when cleaning. Pic 3.
- Started with small scrub pad, but that got old quick. Used brass brush and flat screwdriver for the thick stuff. Once clean, I flushed it all out to make sure crap did not stay in the diff. Nice thing is the new diff cover has a magnet in the bottom drain plug. Pic 4.
- All finished in Pic 5.
Now while spare out, I power washed it. Going to paint any rusted areas with black Rust-Oleum and then hit underside with Amsoil HDMP.
Some more info in this Gen 1 thread.
http://www.fordraptorforum.com/f5/ford-performance-diff-cover-58042/