Well, I picked up the new fenders last Friday and finally had the time to start the procedure.
Its a bit more work than I thought, took me about 3 hours to get to this point. If I have the energy I'm going to try putting it back together yet tonight. Found a few other problems along the way, screws missing, chain case is leaking (cover is warped), exhaust springs missing,...............well, back to work.

Did you ever run an aftermarket can? I think i read a service bulletin somewhere that said to put rtv gasket sealer in between the two bottom bolt of the cover. Are you sure it is warped.?

WOW a warped chaincase :beerchug: welcome to the club

I hope you ran aft can at some point for this to happen... How many rivets did you have to drill out to uncover the beast and are you getting new rivets from a poo dealer or hardware store? Are they the 3/8 rivets?

Yes this is 20 questions....

Never ran an after market can, always stock. When I crawled under to drill out the rivets I noticed the gear oil. When I looked closer at the bottom of the case, I can see that the cover is tight at the bolt locations, but as it comes around the bottom side there is a gap. No scratches or marks of any kind. Long way between bolts. :banghead:

The rivets are 3/16. A buddy gave me a box he had around and I bought a bag of 50 from the dealer and I'll take back what I dont use. Dealer rivets are black, others aren't. There are 19 rivets on one side and 22 on the other. I'm using the unpainted ones on the bottom where they can't be seen.

Got the panels on, just have to mount the hood tonight. Too much stuff to fix now with the case, have to go talk to the dealer about trading.

Now that's gonna hurt!!! Let us know how little $ the dealer offers you.

Seriously, hope the dealer takes care of you. With "new" left-over Fusions going as cheap as they are, doesn't make the used ones worth much............ :banghead:

I have accepted that I will probably own (be stuck with?) my Fusion forever...Sooooooooooooo

Time to start the heavy modding!!!!!! :div20:

there have been some that were stock and the cover leaked too.

Talked to a couple of dealers last week and been offered around $4500 mark depending. With used Fusions going for around $6000 here, thats not bad concidering what this thing needs in repairs right now. I'm scared to drive it another season. The clutch side crank seal is puking oil like a drunken frat boy.

$4500....So when's the new sled coming? And what'r ya gettin???




"puking like a drunken frat boy" :smilielol:

A word of advice is that when installing the rivets they are only effective on an acuurately sized hole and if the holes are somewhat oblong it may be a good idea increase the hole size to the next o/s rivet and install stainless washers on the opposite side you pull the pin through, regardless. I also go a step further and install stainless rivets on the bulkhead, but I imagine they're probably aluminum on the plastic covers. Good luck with whatever you decide. Jeff P.S. If you think that takes a long time try stripping a complete sled down to bare bones.