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From: At my Bar drinking and wrenching in Lafayette Colorado
No. You can get the cover off without dropping the pan. It takes a little prying, wiggling and force, but the cover will come off without dropping the pan. I do it regularly.
wow, didn't know that Lars, thanks
How hard is it to get the cover back on?
Of COURSE Lars is right!
You can get it back on if you snip the little tabs off of the back of the cover. Just make sure it's not bent from pulling it off (lay on flat surface to ensure straightness).
I did mine this way last summer, and no leaks so far.
From: At my Bar drinking and wrenching in Lafayette Colorado
Originally Posted by SIXFOOTER
wow, didn't know that Lars, thanks
How hard is it to get the cover back on?
It's not the cover itself that really interferes when re-installing it: It's the end tabs on the seal, since the seal gets captured between the cover and the pan. If you trim the captured end of the cover slightly and then trim the pan end gasket "ears," you can pop the cover right back into place with little difficulty. I like to do it "dry" a few times before applying the sealant. Once I've verified fit and installation process, I then apply the Permatex Silicone Sealant, with an extra wad of sealant at the trimmed tab location. I haven't had one leak yet.