I'm thinking specifically of when you're in an overtaking mood and keep in third (diesel!) for some time waiting for clear traffic. What if any affect can this have on the engine, gearbox or both?

As long as you are in the mid rev range, it will do a fat lot of FA to the engine and box, just use more juice

So there is definitely less load on the gearbox at say 40 mph in third rather than 40 mph in fourth?

Marginal, I would have thought, unless you're accelerating heavily.

Too low rpm in a gear, and too high, have obvious downfalls.

Anywhere else is fine - just might find some gears more "comfortable" to drive at a constant speed in than others.

long as it isnt below 1500rpm or above 4000 for long periods I;d have though youd be ok

Stay in the gear that is most flexible for the purpose you're likely to need it for next.

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:iagree: