Update on the diff problem for those interested:
On exchanging parts with the front diff it turns out that there is something wrong with the rear diff housing plates, diff plates, or diff joints. Its very odd because they seem totally flat and I've checked them with straight edges, etc. The weirder thing is that in the course of troubleshooting, I swapped in each of the front diff joint/plates in turn - now, if I swap in either one of the front diff joints it runs smooth. The front diff also runs smooth with either rear part substituted, but not both (work that one out if you can!).
Anyway, during the course of substituting, I realised that the front diff joints actually fit the rear joint perfectly and also the housing perfectly. The front diff joints are all metal, built to higher tolerances, will conduct heat away from the rear diff and you can still replace the diff plates if they get worn (more easily in fact, since you don't have to glue them on). So since I have to replace the rear diff parts anyway, I'm just going to order front diff joints and some diff plates to go in the rear.
However, I have a problem in that I can't see any of the spares listed yet in any of the UK stores that I know about (apart from the actual diff plates, which are TA04 parts). So none of the front/rear diff housings or joints are available yet as far as I can see! Is this true, or do I just not know where to look? If anyone knows where I can get spares for the DI at the moment, could you please let me know?
Part no is:
9808059 Front diff joint L&R (MJ1 & MJ2)
Cheers
James