David,
I know the place, been there for months... doesn't it sound like a stone in a tin can?
Replaced:
- engine mounts
- transmission mounts
- down pipe (de-cat'd)
- mid silencer
- exhaust system rubber supports
Whilst all of the above improved the vehicles drive (it actually eradicated a much annoying cabin rattle at idle) the dreaded rattle did not go away.
Overhauled transfer box (had minor leak from input shaft seal) & while doing so scoped all areas surrounding gearbox for loose parts, to no avail.
Have lately concluded it is the torque converter's plate being cracked. This appears to be relatively common in Td5 Autos... I have read at least a dozen posts where similar symptoms are described. Even Ashcroft makes mention of it.
There is small plate (~2" diam, 'D' shaped I believe) screwed at the bottom of the TC housing, it looks as if one could remove it and run in with some sort of inspection device... currently planning on buying an endoscope type USB camera to try confirming the problem before I shed £1200 in a new TC.
Rgds
Matt