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Hi everyone. I am a recent freelancer owner having acquired one for my better half now we have a ten month old son and associated clutter to transport about. It has developed a clunking sound recently around the front end I think.. I cannot pinpoint as to when it does it though I do think it...

Rather too low than too high.Could be a few things.Did you have the heater on ? Did this start blowing cold. May be your thermostat is stuck open- does the temp behave normal on shorter runs. Were you on the m way at a steady speed.If it is a diesel the cooling can be too good and almost...

I would of thought you need a centre diff to stop transmission wind up as this is what the vcu does as well as allowing automatic 2w 4w drive when required

Checked everything over i could lying underneath it in a field all fine, engine temp was ok throughout the trip (glad i fitted an electric fan the week before ) and no odd smells apart from my feet sweating that is.

Yeah had the windows open most of the journey.Not noticed it before as i not towed 100 mile non stop with it before usually on local trips with horse box or trailer.

Been away towing the caravan this week with my 200 tdi and noticed after a while there was a tremendous amount of heat coming from the gear box tunnel.I dont have carpets in at the moment but the sound insulation is still on the tunnel so i dont know if the lack of carpets made the heat more...

I just done both of my sill with box section.I cut off both inner and outer sills leaving about an inch as a channel.Made my own replacement mounts then once all cleaned up puddled welded the box section in and seam welded all along the sill that i had left in both inner and outer.Just tacked...

Put your hand down the back of the engine up against the bulkhead and feel for it blowing out between cyl head and block.My bet is head gasket going here its a known weak spot. You prob wont get any of the usual cyl head gasket symptoms such as overheating , oil in water etc.Mine ran with this...

By doing what James suggests you wont be actually putting power through the frnt dif.A process of elimination.

I fitted mine into the passanger side underdash stowage box with a remote for ease

OK thanks for doing that much appreciated.

I am about to replace the sills ,or what's left of them with box section. I want to make up some new body mounts to fit onto the new box section. My question is what size holes do I need in them for the body mount rubbers to fit through. Any help much appreciated thanks.

It attaches to the top of rear axle on a mount next to the rear dif. then there are 2 arms that attach it to the chassis.

Only thing i would add to james's comment is the drop arm can be an utter ****** to get off the box output. Be prepared to struggle or just do as i did and spent a tenner on a new arm nut and lock washer.

Def sounds like the a frame ball joint to me.

i take it your body mounts were in fairly good nick then

Lol looks spot on to me. I love the old 200 got one myself. The only electronics is the clock (oh and immobiliser if fitted) . keep it nice and simple fine by me.

Looking good there. I just picked up 2 lenghts of that box section for 30 quid ready to do mine.Did you leave the inner sill in place or hack that off as well?

Dont know about cyl head cant help there .All i can say is that when i changed my water pump as the bearing was on it way out it took ages to get the air out of the system properly with cab heater being the only real symptom of the air lock.

Ok thanks for that.