I really was in the same situation, even bought the bolt! Took it apart and reassembled it and it went together OK. I can't remember what meshed but it did!

I think I have seen that some people will hammer a torx into a damaged one (obviously over size) BUT I have never done that myself so please get someone to confirm.

I had this issue but for the life of me I can't remember what it was. I think it was a case of taking it apart and refitting it and jiggling it a bit. Sorry I can't be more helpful but it did go back together - but I didn't change my CVs. Mine was the left hand side.

I know what you mean about getting it through its mot, but sometimes that extra effort means it will get through the next, then the next.... With the standard hoses I have cable tied my calipers to the springs to do further work. I ended up swapping out my axle case after doing my swivels!! I...

I think the standard method for heating dinatrol etc is placing the container in a bucket of warm water before you use it. It applies easier then. I used Lanoguard and fluid-film on my chassis on the outside. I did this as its an old 1993 chassis and I need to monitor it for rust and keep on...

I ended up changing the pipe on the right hand side too. But in the end I virtually did an axle refurb. Changed the front axle case to a like new 300tdi one, which then required new hockey sticks so new bushes in those, both swivel housings, new bearings, new calipers and new discs. I changed...

I made my own lines from the flexi to the caliper. The hole in the bracket on the swivel housing is often cut into a slot to allow the the removal of the caliper whilst still attached to the flexi so you don't have to bleed the brakes every time you take off. I can't help you with part numbers...

On looking at the state of the vehicle I can't see the mechanical side being treated very well. I don't really think I would want this even after a full restoration.

Thanks dag. I will not be looking at doing it until next year but I will look at sealing like you suggest.

That thread was damaged when using it to replace one that had been fitted with the incorrect bolt (had a fine thread fitted instead of a coarse one). That ended up needing a repair and I always urge caution when people are doing this job.

https://www.mig-welding.co.uk/forum/threads/mig-for-car-repairs-thin-gauge.132709/ Look at the last post on this thread. He may be a bit far from you and also I can't comment on the welder as I have never used one, but just in case it is of interest!!

I have never really been a fan of snorkels/raised air intakes as I don't really intend to take the defender through water that deep. I think one of the reasons I wouldn't want one is due to potential air noise on motorways etc, but saying that I haven't travelled in a defender with one so I am...

I saw a thread somewhere about a guy that had an issue with oil pressure. I can't remember exactly what the outcome was, but apparently there was a hole in the filter that allows the oil to flow through and on the cheaper filter the diameter was smaller restricting the flow. I was astounded...

Full service history???

I had exactly the same with mine. Replaced with cunifer and brass fittings to hopefully reduce the chance of it happening again. Then added a thick coat of Lanoguard grease.

Look at the image of the bolts I posted in your other thread and note the coarse thread bolts (B & D) have a spring washer. Are yours the coarse thread and if so should they have a spring washer too? Note the fine thread bolts have a longer threaded section.

Firstly, have you fitted a low coolant alarm? 300tdi suffer badly if coolant level drops due to the high level of the water pump. I think you may have a head gasket failure if its white exhaust but I have no experience with this so better to wait for the experienced folk to give you advice on...

I am not an offroad driver, though I do drive across a moor often but I am careful not to break through the grass into the peat. I do this in a 1993 90 and whilst it does this comfortably, I am sure a new Defender would be more than capable of the same. The big differences in my mind are...

Depending on what time you have available, look into electrolysis. I cleaned lots of bits using that method including swivel housings, hubs, stub axles, brake shields, axle cases, hockey sticks and lots of other bits. I then finished them with phosphoric acid before painting. Electrolysis only...

https://forums.lr4x4.com/topic/24801-swivel-bearing-preload/