Red90

https://www.jegs.com/installationinstructions/500/555/555-631010-116.pdf

Yes. There is adjustment on the servo rod length where it engages the master. If it is too far in, the master will not release. Possibly the addition of the vacuum pump put it over the edge. Back it off and see.

I would suspect servo being adjusted incorrectly.

That is not possible on a 200TDI as the charge light circuit has a diode to prevent the alternator back feeding the light and switched power circuit.

Check the engine ground and the main loom ground. Charge light is simple to test. D+ wire disconnected the light should go off. Grounded , it should turn on.

With a weekend of camping gear and two people, I got 2270 kg. 1120 front, 1150 rear.

Did you adjust the flasher? The adjustment is to set the trailer light.

The method is correct.... Yes, an empty 90 is nearly perfect 50:50 weight distribution. Now, I would suggest 30 front and 35 rear. The vehicle dynamics are better when the rear tyres have a slightly higher rolling radius than the front with the full time 4WD.

Yes. There were a variety of styles through the years. You just need to make sure you get the correct length as different gearbox arrangements use different length shafts.

ETC8191 https://www.turnerengineering.co.uk/etc-8191-nut-connecting-rod-c2x20634932 http://www.paddockspares.com/etc8191-nut-for-con-rod.html https://www.island-4x4.co.uk/conrod-etc8191-p-4996.html

You are supposed to use new nuts on the con rods as per the workshop manual.

Yah. He was making it sound as if you could set pedal height and freeplay separately. I'm not really thrilled with putting constant tension on the rod and an impact every time the pedal is let out. And then you can't set free play independently. I just went and added an adjustable up stop. Took 5 minutes. The stop plate is still on the pedal itself. They just stopped putting the screw on the box.

You say "Set pedal height with the push rod nut then use the other nut to give you your 1/4" free play." Please explain.

??? Just got one of these fancy new pedal boxes. The screw limits maximum travel. There is no adjustment for resting pedal height.

You need to trim and add longer bump stops. Wider flares if you want the tyres covered. A lift will not change those facts. Lifts do not affect tyre clearance.