Know this post is older but one thing in particular stuck out. Ignition switch fault - DO NOT LUBRICATE WITH GRAPHITE BASED LUBRICANT (powder especially, but equally grease / lubricant less) - Graphite is conductive and if it gets in the wrong places will cause problems forever more...

Valid Point, I'll revert on my next tankful and see what happens, and report back. In sport or normal, I'm light on the throttle and the journey is fairly flat so acceleration, incline etc will have negligible if any effect. (M180 J1 to M62 J29 via M18, only about 2-3miles of A road total...

Had my D3 (2.7D, Auto-box) for about 2 years now, more usually used for the daily commute (Doncaster > Leeds (circa 35 miles (33 on motorway) motorway). The other week i decided to see if there was any significant difference in engaging 'SPORT' mode (contradication, lol) on the gearbox. I...