BennehBoy

Wish my brain was

Air inlet temp sensor is part of the MAP sensor on the inlet manifold, the sensor in the airbox is the AAP (Ambient Air Pressure) sensor. Check values by plugging in nanocom/hawkeye/testbook.

Did things improve?

Did the TD5 110's ever get the cat down pipes? Just asking as many a D2 has lost power due to the cat clogging...

They're a sealed unit. I'm guessing it was a 50 quid ebay job? Get a replacement, and try avoid those in future. Genuine are now ~ 400 quid so really not worth fitting. Timken who made the OEM units have stopped making these, but some places still have a few in stock at about 250 quid. Britpart do an 'oem' one for about 150 and tbh I've only heard good things about them. Most of the chinese knock off ones (and also bearmach ones btw) have only 55 teeth on the reluctor rings instead of 60 and cause havoc with the ABS/TC, so avoid if not fitting in matched pairs/all four.

Check that you've coupled the boxes together with the correct length bolts first of all, the bolt on the front side of the LT230 which goes in through the R380 needs to be the shortest one otherwise it can strike the gears inside.... If you drop the oil and remove the rectangular inspection plate you can see the end of the bolt inside the case. Are these newly rebuilt boxes, or just ones you've grabbed used? I'd be talking to whoever sold them to you/fitted them if the noise persists and/or there's any bearing whine.

I'm in Huddersfield btw - if it does turn out to be a shagged box I've got a spare one sat in my shed that you can have a for a pittance. Not after big money I just want rid, I bought it for a transfer box it was coupled to. I've also got nanocom & lots of tools.

Long legged gear pullers/separators - oil seal collar & other bearings. Impact gun - for the fifth lay gear nut blind bearing puller, for the support bearing track in the pinion Press Various drifts & mallets

Sounds like a valve block issue, usually caused by debris from a disintegrating clutch pack. Was the ATF dark at the first oil change? Was the problem there before the first change, these boxes are renowned for failing once fresh oil has been put in because it acts like a detergent and frees up any carp to float about. It's probably rebuild time.

I refurbished my own R380 simply because I didn't trust a professional place to actually replace all the parts that wear the most, all bearings, baulk rings etc. Cost me 200 quid + time. It's a pretty easy rebuild if you have the right tools.

Leak down test?

Should really replace the washers every time, and only use genuine ones. Does injector 3 have a different end letter to the rest, what are the codes?