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"I have a feeling the disks are getting covered in wet mud while deep in the ruts and that's what is wearing the pads" In my experience that's exactly what is happening. One of my yearly trips is to a mud covered area of botswana - about 2 weeks and about 1500 kilo's covered and I will go...

Your centre diff-lock will indeed send 50/50 power to both the front and rear alxe When all this power get's to each axle the axle doesn't have a diff lock so it put's it all to the wheel with the least amount of traction That's on the D1 On the D2 onwards they got clever by taking the pesky...

That small pipe with a T-piece will work. During my testing I used the connection that goes onto the top of the FIP with a t-piece. a lot less heat in that area Mine is on the top turbo hose thereby showing me if there are any leaks as well Used a valve from a racing bicycle tube thru the...

Where's the christmas Grinch on here - surely there must be half a dozen or more people that would qualify

Is that an extended sump with a temp sensor in it ? What kind of temp's do you see at highway speeds

On my D1 300 tdi there were a fair amount of studs - maybe it wants to come out more parallel - is it a half inch all round or just at the bottom / top ?

What injector was it - if it's number 4 then I need to do mine as well

No - I use the std API gl4 spec. This trf box has got 600k on it - a bit whinny on very light throttle and a fair amount of sloppyness between it and the diff's - although I change oil at max 20k and after any water excursions or a long towing session. Then the box seems to leak about 200 ml...

In saffa land the oil around the sump bolts is from the intermediate cross shaft leaking into the cavity between the trf and g/box and then the wind doing the spreading. No amount of sealant or gaskets between the trf box and g/box seems to contain the oil Bloody annoying leak - but at least the...

I have some mates with the checker plate on the wings. In our heat you will burn blisters on your hand's / skin if you even touch it for a second. It looks good though

So my experience only If it is exhaust gasket / exhaust manifold warping - you will see the streaks of black soot around the manifold very easily Maybe a good clean with electrical spray first to clean everything is a good idea then the block is black so a wipe of the finger should show it up...

Well I disconnected the standard one on my 300 tdi years ago and get a whopping 1 bar of boost vs the 0.9 to 1.1 bar the manual says is safe

Never heard of a boost controller for a 300 tdi Or I am missing the point ?

Could it be that the sealent you used is not good and the stuff is busy seperating into it's base chemicals . There must be some sort of liquid mixed into the compound to enable it to flow ? Just guessing here of course

R u sure that's engine oil and not a mixture of "old" engine oil and diesel ? I don't think you are ever going to get it completely dry. And if it doesn't drip after 1 hour of standing it's called a "sweat" of oil

On mine the OD of the leak off V on injector 1 is slightly thinner than the V on the back of the IP. So i have a good piece of wire around that pipe connecting the two

When I change my diesel filter - I will fill the filter and run the car for 2 min's , then open the top bleed screw to get the last of the air out and sometimes i am a bit frisky on the undoing of the bolt and the jet of fuel will be 1 foot high, - that's at idle If I hand pump it it will still...

Your post re the engine dying sounds like the lift pump. They can be quite temperamental/shyte . A cheapish part and may solve your hard starting as well

The leak off pipes are connected to each other via that V looking thing. Injector 4 to me is the one nearest to the bulkhead / driver and the one side of the V doesn't have a hole to transfer fluid across and obviously wouldn't have a pipe connected to it Maybe two of the V's are in the wrong...

The banjo bolt - that connects the leak off pipes to the front of the injector pump - has given me the same issues in the past - albiet randomly I suspect the copper fitting joining the incoming leak off pipes to the return pipe was my issue, but I found copper washers somewhere and replaced...