Drop gas tank for IRS differential cover

kahukub · Oct 4, 2017

I know you have to drop the IRS to replace the differential cover. My question is if I can drop the gas tank remove it from the car and have access to replace the differential cover. Would there be any obstacles that would prevent me from installing the new cover? I have used the search button and I have found so much great information about dropping the IRS. And I have also found so much information on dropping the gas tank. Just not enough information for this particular question. So in the end it’s either gas tank or IRS I just wanted your opinion.

Winter is around the corner and it just started leaking a few days ago. Unfortunately I don’t have a garage so I’m trying to get this done ASAP before the first freeze in a week or two. I know I could replace bushing, shafts, gears while the IRS is out but I just need to get the cover fixed until probably spring. If I can go gas tank route I would do fuel pump and filter while that’s out. I have a shop I can use but the funds are already dedicated to other parts of the car. Thanks In advance for any advice.

SVT_Troy · Oct 4, 2017

You do not need to drop the gas tank in order to drop the IRS. You mentioned doing some Fuel stuff, do you have a pprv delete done?

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kahukub · Oct 4, 2017

SVT_Troy said:
You do not need to drop the gas tank in order to drop the IRS. You mentioned doing some Fuel stuff, do you have a pprv delete done?

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Hey man thanks for the reply. I know I don’t have to drop the gas tank to drop the IRS. I was wondering if I can drop the gas tank instead of the IRS to change the differential cover while the IRS stays on the car. And no I do not have the PPRV delete done yet.

kahukub · Oct 5, 2017

The pprv delete is on the future list.

SVT_Troy · Oct 5, 2017

Ok my apologies for not fully reading. No you do not need to drop the irs to remove the diff cover but man is it a lot easier to just remove the irs. Making sure you have it sealed properly on the assembly is tough with it in

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kahukub · Oct 5, 2017

Very true, well it is an option which is good. I mean it kinda sucks not haveing a second hand for the IRS. I guess I can just suck it up if I decide to go that route.

SVT_Troy · Oct 5, 2017

Dropping he IRS by yourself sucks but it also can be done with a jack and a few pieces of 2/4. Assembly is always the most challenging.

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kahukub · Oct 5, 2017

SVT_Troy said:
Dropping he IRS by yourself sucks but it also can be done with a jack and a few pieces of 2/4. Assembly is always the most challenging.

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Man I figured, well thanks for the reply I know it’s not extremely complicated but more time consuming. I guess I’m just being lazy and looking for a way around it but we all know that laziness will cost you more in the end. I should probably just do this the proper way and be done with it.

Coosawjack · Oct 5, 2017

Just curious....what's wrong with the cover that's on it now??

hotcobra03 · Oct 5, 2017

There is a brace between tank and irs.

Center is very easy to pull out..

You can do cover in car..center will move forward enough to remove cover..just takes along time to drip clean enough to re seal..

First time i did mine i only removed 1 side and slid center off of axle..

2nd time i pulled both so i could use a jack to hold center..

Center isnt that heavy.im just getting old.

kahukub · Oct 5, 2017

Coosawjack said:
Just curious....what's wrong with the cover that's on it now??

It has a pretty good leak from the differential. I need to drain and reseal but I’m thinking of replacing the entire cover with Ford Racing cover while I’m in there.

Rich'sTRsvt · Oct 5, 2017

You don't have to drop the whole irs, you can just drop the pumpkin. You can pull the axles out by just taking off the calipers and removing the bolts that hold on the hubs. Make sure to mark where the camber bolt is so you don't have to do an alignment. The hardest part is removing the parking brake cable.

kahukub · Oct 5, 2017

Rich'sTRsvt said:
You don't have to drop the whole irs, you can just drop the pumpkin. You can pull the axles out by just taking off the calipers and removing the bolts that hold on the hubs. Make sure to mark where the camber bolt is so you don't have to do an alignment. The hardest part is removing the parking brake cable.

Sweet thanks for the advice I belief i watched a whole segment somewhere on YouTube about this. I may just end up going this route.

BLOWN9646 · Oct 6, 2017

Just did the FRPP cover myself couple months ago. Easier to fill while it's out, too

Dave.O · Oct 6, 2017

what hot cobra said.
disconnect driveshaft if necessary.
pull axels
Remove 3 bolts that hold diff in place.
Slide forward.
I recommend using lube locker in stead of sealant.
fyi, not exactly sure how much it actually ways but it sure felt like >85lbs the other day when moving mine. getting it out isn't bad, putting it back in by yourself can be a test of strength and patience. if you can avoid pulling it all the way out would make your life easier

If you are pulling it all the way out and adding FRPP cover I highly recommend studding it and ditching those factory bolts which can easily strip the threads in the housing. do not over tighten them (ask me how I know....)

ITSTOCK · Oct 7, 2017

Dave.O said:
what hot cobra said.
disconnect cat back
disconnect driveshaft.
take wheels off
remove upper and lower control arm bolts that hold hub on
remove tie rod bolt to lower control arm
remove 8mm (I think) bolt that holds the brake cable
remove lower shock bolts
remove axle nuts
pull entire hub and set to side
pull out half shafts
Remove 4 bolts that hold diff in place (two on the pumpkin by the driveshaft, and the two outer ones that are on the cross member).
Remove 2 bolts that bolt through the diff cover (a ratcheting wrench works great for this)
remove center section
I recommend using lube locker in stead of sealant.
fyi, not exactly sure how much it actually ways but it sure felt like >85lbs the other day when moving mine. getting it out isn't bad, putting it back in by yourself can be a test of strength and patience. if you can avoid pulling it all the way out would make your life easier

If you are pulling it all the way out and adding FRPP cover I highly recommend studding it and ditching those factory bolts which can easily strip the threads in the housing. do not over tighten them (ask me how I know....)

For what it's worth, I just broke a cover with the diff brace and replaced it with the FRPP cover. The FRPP cover is a MUCH stronger piece. It took me under 4 hours to do the entire job with air tools. It's very easy if you follow what I have above.

Drop gas tank for IRS differential cover

kahukub

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