Sorry for the essay but I've had some great advice from here in the past and hoping I might get some again.

I'm looking to see what peoples thoughts are on the following issues as my MOT is coming up soon and I'd like to get all this sorted properly as I need the car to be reliable for work and it is in otherwise excellent order.

Brakes - I've noticed for a while that the rear disks have a band of clean metal which is presumably getting contact from the pads but there is also a rougher band which usually shows rust. There's plenty of material left on the pads and I can't figure why the discs would be appearing like this. Also, there is a little creak from (I think) the brakes when getting out of the car with the hand brake applied, as though it is giving just a tiny bit. Is it possible that both calipers are not floating freely and causing uneven wear? I have 312mm discs on the front but to be honest seldom push the car hard at all. Could it be that the fronts are doing so much work that the rears are just not getting a chance to wear? I have been toying with the idea of picking up some 256 rear calipers and carriers for when I replace all the discs and pads soon,more for looks than anything else but it all depends on getting a good set at the right price.

Bushes - I'm fairly certain the console bushes are totally shot as I can cause play in the wheel by pulling and pushing it when stationary. The play appears to be coming from the rear of the front wishbone and when dry there is a light creaking/squeaking over bumps and during acceleration deceleration as well as a feeling of slop in pick-up when taking off. I plan on getting some powerflex bushes as they will be easy enough to fit but as I understand it the front wishbone front bushes are usually fine. Would it seems ensible to just leave them at the moment and see how I get on with just the console bushes?

As an additional issue, I think the dogbone bush is shot too. For several reasons. 1. the slop in engine pick up and on deceleration, 2. when I was looking at the engine with the bonnet up and it seemed to twist a fair bit more than I would expect it when being revved, 3. My gear changes don't feel as smooth and direct as I would expect them to and improve when you blip the throttle (possibly twisting the engine back to a position of better alignment.) Does this seem sensible? I would like to use the super pro replacement bush but ideally need to find a used dogbone I can fit it to in advance so I can just swap it in. If anyone can help me out here I'd be happy to buy it or send you my old one in exchange. Alternatively the standard dogbone is pretty cheap, is the uprated one really worth it?

...relating to the dogbone - The car has had a light whistle from the turbo since prior to purchase. The original issue was obviously whether it was symptomatic of a dead turbo. I agreed with the seller that we would get the turbo to a turbo specialist to check it out and replace if it was worn. Oddly enough they inspected the turbo and said it was in perfectly good condition, vertainly not in need of replacement or rebuild. Their assessment was that it was the gasket between the manifold and the turbo creating a leak and a replacement gasket was fitted which seemed to resolve it. However the noise has returned and when I revved the engine with the bonnet up I noticed a small puff of smoke from under the engine cover as the revs went right up. Could it be that the twisting allowed by the dogbone could be contributing to loosening the seal around the gasket? I'm not sure what is mounted to what with the turbo and engine etc but this occurred to me as a possibility?

Finally, when replacing a light builb teh other day I stupidly thought that the plastic hex bolt at the top of the headlight fitting was for undoing the cover. Of course I realised it wasn't and just used the clips but as I've turned this screw a few times it won't be in the same position as before and I was concerned it may be to do with the headlight alignment. Anyone know what this allen head plastic thing does?

Thanks

49 views and no responses ... Maybe i should split this into separate threads.

Edited 29 August, 201114 yr by Dougie S

Sorry, I'm not too hot on brakes but sound like uneven pad wear. Maybe check the pad surface is even and that discs themselves are not warped?

The console bushes are usually the ones that wear most. Best way to check, as with most things, is to have a good look. Jack up the car and get your head under; rock the wheel and look at the bush, it will be obvious if there cracks/fractures in the bush.

As above for the dogbone really. The engines doo move quite a but on the mounts, but they are heavy diesel lumps and the reason for rubber mounts is cabin comfort after all. Swapping the bush is a 10 minute job so you don't really need a replacement mount.

i wouldn't expect engine movement to rupture the exhast/turbo gasket, plus a lot of the movement should be taken up by the exhaust flexi. All diesel turbo's 'whistle' quite loudly when on boost, its the traditional 'siren' sound that spells the end of your turbo life, especially if it makes the noise at low revs.

Plastic thing on lights is either for alignment or switching from LHD to RHD beam pattern, sorry I can't help any more than that.

there isn't a gasket between the turbo and the manifold, it's cast as one piece?

Apologies, not explaining myself very clearly then. i know it was a gasket associated with the turbo in some way. just presumed it must of been to the manifold but Im sure you're right about the all in one casting . not sure which gasket it would be then. Had the old gasket but i think i threw it out.

just meant that if that's what a garage said was the issue and they fixed it...

I was reffereing to the gaskets between teh turbo and the down pipe. I doubt they'd rupture due to engine movement, even if your mounts were on their way out.

Finally, when replacing a light builb teh other day I stupidly thought that the plastic hex bolt at the top of the headlight fitting was for undoing the cover. Of course I realised it wasn't and just used the clips but as I've turned this screw a few times it won't be in the same position as before and I was concerned it may be to do with the headlight alignment. Anyone know what this allen head plastic thing does?

Thanks

Those are the beam adjusters, Outboard is for Azimuth, Inboard is for height!

Cheers Mike ... any idea what id need to do to check and reset alignment ? not sure what the guidelines would be.