You think a garage is going to knock off £1.5k from a £4.5k repair bill? I don't think that will happen.

If I had bought a car then had to spend the same again to fix it then I may well call it a lemon.

Nope, makes no sense whatsoever, good that it's fixed though. Show us a photo of the part you mean.

Good morning to Yorkshire. Haven't been there for a while, some of it is nice.

https://www.lrworkshop.com/axles-differentials/pinion-flange-pinion-oil-seals

If the diff flange is worn then the seal won't seal against it. Also the seal is different depending on what mud shield your flange has. I am presuming the diff is the same as a Defender, if not ignore me.

I'm going to remove the injection pump gear and pump and reseat them tomorrow and see if I can see anything a miss. Quite what could be wrong I don't know.

Using my Heath Robinson straight edge the cam gear and crank gear are good. Using it across the cam gear and injection pump gear it suggests the outer edge (nearest the outer edge of the casing) of the pump gear is further back. There is a 1.6mm gap between the gear and straight edge, measured...

You could sent the ecu to be tested. Injector loom isn't a great deal of money. Somewhere along the line you will need to buy a suitable scanning tool so you may aswell buy it now.

It might be the horn button. I had that once on my wife's car, I was out and my wife didn't know how to deal with it. When I got back the horn was red hot, been going off for half hour. Still worked after it cooled down which I was pleased about as it's a nice sounding horn.

Thinking out loud so bear with me. Crank gear can't be in the wrong place and cam gear can't be wrong. That leaves the injection pump which has a gasket (although I can't see that makes a difference) and also has the pump rear support bracket. So I can't really see how that would be wrong. Could...

Yes

I thought you said you disconnected the horn from the loom? There is a battery disconnect procedure if your td5 has a bbus fitted.

With a lack of a straight edge I have used the back edge of a hacksaw blade (don't laugh). They all seem to be in alignment, level with each other. Warranty claim has gone in, let's see what happens.

That's an illusion.

Is that the P gasket area? Only a guess as I don't have a 300tdi.

Your TD5 might must have the 2nd horn near the drivers headlight then if it's still going off. If not then it must have been your BBUS sounder going off rather than the horn.

Do you think it's just not running true or maybe the mount plate is bent? Either way it's going to be interesting to do a warranty claim. I'm going to give it a go though.

You can see on the tensioner the belt is running across it at an angle and the belt is too far back on the other pulleys (maybe?) The belt doesn't seem to be catching anywhere apart from the ridge on the tensioner pulley. I haven't taken the tensioner off yet as I wanted some opinions first.

As you slow down and stop it stops? Sounds like a rotational noise, like sticking something in a bicycle wheel spoke. Propshafts maybe? Afraid you will need to have a roll around underneath, jack each wheel up and give it a spin. You can drive with one prop so if suspect take it off and see if...