Replace the starter contacts with a rebuild kit. They are not expensive. Classic TD5 problem.

Also check the injector clamp as they can come loose after refitting as the washer settles. I always recheck them after a 100 miles or so and have found two to be relatively loose. Having said that I have removed and fitted about 40 or so TD5 injectors over the years so the % is quite small.

Always worth annealing new copper washers as they can have work hardened edges from the stamping process. Also a good idea on sump plug and banjo washers etc.

If starter spins and easily cranks the engine then I'd be looking at the ECU earth as the engine earth is probably OK. The ECUs are in different places depending on Disco or Defender. My Defender ECU earth point was on the chassis under the driver seatbox. The Disco ECU is under the bonnet and...

If it was a drive shaft there would be no drive all the time and a horrendous noise from the axle as the broken shaft rattles in the axle casing. My guess is the transfer box is not engaging fully allowing it to jump into nuetral between high and low ranges. When selecting diff lock you may be...

As it only owes me a fiver and my old one is looking very shabby its a no brainer, Worst case I'll dump the spring and use it as a normal damper. I can make up a shroud from pvc pipe and an end cap to keep the crap off the damper rod,

Yes. Heat them to a dull cherry red (not any hotter) and let them air cool before use. Do not quench in water or oil.

It may be an injector rocker is slightly out of adjustment.

Next time it wont start connect a boost cable direct from the battery earth to the engine block and see if it solves the problem. If so its defo an earth fault which is common on the TD5. Check the main engine and gearbox earth strap connections are clean and tight. Take them off and clean with...

Nice one. The pictures are a good reference. I'm going to do all the hockey stick bushes, the shock bushes, the drop arm ball joint, and the track rod ends at the same time as I've recently (two weeks ago) just done the panhard rod bushes. That turned into a two day drama when one of the bolts...

I've just been given a brand new Terrafirma RTC steering damper in exchange for an old 2 ton chinky bottle jack that I bought at a boot fair for a fiver then never used it. I reckon I got the better half of the deal. Anyone got any experience of these dampers? My old OEM damper is 18 years old...

Job done. New bolts were plenty long enough so welded 4mm thick plates over the oval holes and jobs a good 'un. No more clunking and nice new bushes fitted so should be good for another 10 years or more.

Blue smoke is engine oil burning and could be worn rings or turbo bearing. Important to sort it as can lead to an engine run away where the engine runs to destruction on its own oil. White smoke is actually steam and is coolant being boiled off in the cylinders. More often than not a leaking...

That is why I said try the spacer but if it wont start or misfires then remove it. My manual TD5 90 would not run reliably with the spacer fitted (misfired under load) but without the spacer it works just fine. I did initially fit a cheap pattern sensor with the spacer but it would not start and...

The postie would not be pleased with that in his sack.

I may still have to do that as I have ordered some new bolts which may be slightly shorter than the originals.

I always fit the spacer and see if the engine runs. try driving it rather than let it idle. If you are having issues with starting and intermittent misfires when driving then remove the spacer as the sensor is too far from the flywheel to give stable readings. If you use cheap pattern sensors It...

I have some 3mm x 30mm steel washers which I will ream to a good fit on the new bolts. and I'll weld them over the holes. The old bolts had about 12mm extra length when tightened so I reckon that will leave me about 5-6mm spare. I've also just discovered I have an empty gas bottle on my mig so...

So as today was nice and dry and not to cold I thought I'd change the bushes in my panhard rod to stop the annoying clunking that started last week. Easy job, undo the nuts, drive the bolts out, drop the rod, press the old bushes out and new ones in, do everything back up and Robs your mothers...

Cheap switch or a loose connection can cause overheating. Have you got any additional lights wired to the headlamps? If so they should run via a relay. Most peeps just splice them into the existing wiring which melts the switch.