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I've just had a second sealed headlight unit in my 90 200tdi go in a month. Whilst reading the workshop manuals it appears that the older 90s came with sealed units whilst the 300tdi came with reflectors and bulbs. I presume that it's no more difficult to switch from one to the other than it was...

Just to add completeness to the thread; the nut was in some sort of expanding fastner and was eventually released with an angle grinder. Replaced with a more traditional nut and bolt.

You win! One of the UJs was in need of replacement.

My 200tdi has started to make an odd noisy when decelerating. It's a grating turning noise that started off quietly but is now quite noticeable. The noise stops if I press the clutch whilst continuing to decelerate. Any ideas?

Nope. Unfortunatly whatever the fixture is behind the body work (I can't see it too clearly, its got a rounded barrel and I can't get any grip on it at all, fingers or pliers. Not entirely sure that grinding the head of the screw off will cause whatever's behind to drop out either, if that was...

So I had a think of ways I can get some force behind the screw to lift it out and ended up using an old sling from my climbing rack. Putting my entire weight on the sling and unscrewing it doesn't result in any progress. :mad:

Not even that much room to slide one in. Levering from behind the guard just pushes against the body work too much. I'll try again in the morning when I've got more patience and less beer to drink :D

I eventually got all the screws moving with a wrench. The inside two are fine but the outside two just turn and turn and don't move out as I unscrew. I wonder what's up there. Yours frustratedly, James

Thanks. I don't actually get the slightest bit of movement in either direction to wiggle it left and right. I'm going to try tapping.

Thanks. Damaging the bodywork was in the back of my mind and the screw extractor was going to be my next step after that anyway.

I think whoever fitted my headlight guards on my defender decided that an industrial power screwdriver was the order of the day. What's the opinion here about stuck screws? Having tried some WD40, I was going to attempt to get more torque using a screw driving socket and wrench and failing...

So reopening my long dead thread. I went to open the bonnet today and even with my faithful assistant could get it open again. Due to some newly found flexibility in my fingers I'm able to reach the lever the cable pulls on. There's very little movement in it, and jiggling it about I'm unable to...

So I go back out armed with the biggest hammer I can get my hands on and after a few turns of the nut the wheel comes off in my hands. I guess I just had to be more patient with the WD40. Thanks for all the help from everyone.

How "firmly" is the wheel supposed to be attached to the shaft? I've undone the nut but can't get the wheel to budge. I've tried a little WD40 to loosen things a little and tried getting some leverage behind the wheel but no luck so far. Perhaps I'm just a wimp?

The assistant did the trick. She jiggled the bonnet whilst I pulled on the release. I've got my socket set back so I'm going to have a go at pulling some of the slack out later in the week.

A-bar is in the way and I haven't got my socket set to hand.:o

That's what it looks like, I can see the cable through the grill and it's not tight. I can't reach it at the moment, and there's not a spare pair of hands so I'll just have to wait for an assistant :-)

Day three of owning my refurbished 200tdi and I'd like to take a look under the bonnet. The bonnet release knob doesn't appear to be very effective, I've pulled quite hard with little movement and so I can't open the bonnet. Any tips as to what's wrong (or more likely, what I'm doing wrong)...

The alignment of the the steering wheel on my new defender is off by about a quarter of a turn. I wouldn't mind so much but it's obscuring the speedo at the speeds that really matter. Is it just a case of centering the steering, removing the wheel and reattaching it in the correct alignment?

Thanks, that's pretty much what I was expecting to hear. I'll check the hoses first anyhow, it's a '93 200tdi so it's just about old enough that I may have to be careful.