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Well, this is a broad question. If, for instance, you were installing your Flip Top Case while feeding sharks......well, a lot of things could go wrong. If you install it in a dust- and water-free environment (also shark-free) then you lessen the risks of getting something inside your ps2, which would be vewwy bad. Ps2 + Water or dirt = a big paperweight. I don't know about shark damage, myself, but it can't be good.
It's important that you do it with the right tools; I know that knives make good screwdrivers, but don't be tempted to go cheap on tools when modifying something like a ps2. Get yourself a good set of screwdrivers, a mini flashlight, and adult supervision. Lots of it.
The instructions for installing the Flip-Top case are very simple- the worst thing would be to try and force something in/out of place... so be gentle. The same goes for over-tightening, etc.
Keep in mind that removing your Ps2 case voids your warantee. If you install a new case, say bye bye to returning your ps2 for repair/replacement. This may not be such a good idea, especially since Ps2's seem very prone to laser trouble (i.e. the disk read error of death). If your Ps2 is still under warantee, I would say that you should not void it if you can avoid it (I rhymed! sort of). If, however, your Ps2 is >1 year old, feel free to void it, it's gone anyway.
You can always switch back to your old case....provided that you kept it and didn't break it while taking it off. Which you might, they're not very resilient. Don't think that this will fix anything that went wrong- it won't. In fact, I can't think of any reason to want to do this.
Alternatives to flip-top cases exist, and are much safer for the console... Slide tools, Magic Keys, or even homemade "straw keys" can do the same thing, without voiding the warantee or making you open the ps2. My recommendation is always with the magic keys, which cost about $6 US and come bundled with Swap Magic (sometimes).
Overall, it's not rocket science to change your ps2 case, but that dosen't mean you shouldn't do it carefully. But, in the rare case that something does go wrong, I'd recommend slide tool/magic keys instead.
Brilliant!
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