Whenever we went to the drawing board to figure out a solution on how to replace the bladder in a 2000 Cobra R fuel cell, we landed on the idea of just putting a regular fuel tank back in the car. Replacing the bladder is expensive. To the tune of $3,000+! We get it. You have to pay to play. However, we liked the idea of a regular fuel tank due to cost. Not to mention, we drive our cars. Not a lot, but more than most.
Once we figured out the fuel tank stuff, the next task was to create something that looked like the car still had a fuel cell. It took a few trial runs, but we got it right! From the ground, both Cobra Rs look as if the cell is still instilled. I'd say mission accomplished. So, if you own a 2000 Cobra R Mustang, just buy the SVE conversion kit and put the factory fuel cell on the shelf.
After the 2000 Cobra R conversion kit was sorted, we figured that other 1994-2004 Mustang owners would like the idea of installing the cover onto their car. This is why you see just the fuel tank cover kit. It fits all 1994-2004 Mustangs with an OEM style tank.
Product Links
Watch
Tool List
- Jack & Jack Stands
- Microfiber Towels
- Ammonia Free Glass Cleaner or Waterless Wash Product
- Scissors
- Isopropyl Alcohol
- Panel Removal Tool Set
- Tank Support Tools (wood, plastic, etc.)
- Dead Blow
- 1/2" Socket Set
- 1/2" Extensions
- 1/4" Socket Set
- 1/4" Extensions\
- Small Flat Head Screwdriver
Torque Specs
- Fuel Tank Strap to Body Bolts - 26 lb-ft
- Nut Plate Bolts - 9 lb-ft
Installation Instructions
Step 1: Prepare the Vehicle
- Either lift the car or support it securely on a lift to get it as high and as safe as you can.
Step 2: Remove Harness Clip
- Once accessible, dislodge the fuel tank harness clip at the rear of the tank if equipped with a pry tool.
Step 3: Support the Fuel Tank and Remove the Fuel Tank Cover
- Find some areas around the fuel tank that won’t interfere with the factory cover and support those areas the best you can.
- Once the tank is supported, loosen and remove the 13mm bolts securing the passenger side fuel tank strap to the body of the car.
- Before removing the front driver side bolt, be sure to support the tank cover as it will drop once the bolt is removed.
- Swing the strap out of the way and then carefully maneuver the cover to remove it from the car.
Step 4: Remove Driver Side Tank Strap
- To remove the hinge dowel from the driver side strap, push up on the strap and take a flat head screwdriver and pry the dowel through the large hole that is facing the passenger side of the car. Once the dowel is out simply remove the strap.
*Note: If you are also installing the full conversion kit or a new fuel tank, at this point you will remove the old tank and install the replacement tank. Reference the video link above on how to remove the fuel tank. Installation will be the reverse of removal.
Step 5: Prep the New Tank Straps
- Take the tank straps and wipe the inside down with isopropyl alcohol and a microfiber towel.
- Align the provided adhesive-backed foam with the strap and begin installing it onto the strap. DO NOT stretch the foam, let it lay in place and press it down so it properly adheres to the surface. Once you get to the 90-degree bends, make sure you fully seat the foam into place. Continue installing the foam until you reach the end of the strap just before the final bend. Cut it even with a pair of scissors and then go back over the foam to ensure it is fully seated.
Step 6: Install the Nut Plate
- Install the (2) provided speed nuts into the body of the car. The nose of the speed nuts will face up.
- The small holes in the nut plate are offset to one side from the center line. The offset holes get positioned to the rear and the welded nut will face up.
- Hold the nut plate into position and loosely install the (2) provided bolts. You will fully tighten these at the end of the install. Leaving these loose will help you install the fuel tank strap.
Step 7: Install the Fuel Tank Cover
- Before installing the new cover, verify the placement of each strap by holding them in place. The driver side strap is the smaller of the two.
- If possible, grab the help of a friend as it will help with the remaining steps. If that is not an option, grab something to help hold the tank cover in place. Ensure you cover whatever you are using to hold the cover with something like a microfiber towel to prevent marks or scratches.
- Position the new cover in place. It will only install one way.
- Take either one of the straps and hold it in place. If the bolt holes are not lining up, you may have to tap the tank with a dead blow or hammer where the tank makes contact with the strap.
- Loosely install one of the provided bolts by hand. Then install the other bolt and run them both down but do not fully tighten.
- Do the same for the other strap.
- Once all of the bolts are installed hand tight, go ahead and torque them down to 26 ft/lbs.
- Fully tighten the (2) bolts holding the nut plate to 9 ft/lbs.
- Reattach the harness clip to the tank. You may have to lightly tap it with a dead blow.
- Remove the supports holding the tank and whatever was used to hold the tank cover.
- Wipe the tank cover down to remove any smudges and get the car back on the ground. You have now completed the installation.
