Originally Posted by Mike1

Don't want to worry you but read this

http://www.turbosport.co.uk/showthre...rth-4x4-Owners

The reason I remember to search for this is because my Mom always used to give me the Motoring section of the Daily Telegraph - in the 'Honest John' section which was a Q and A part there was a letter with a pic of an exploded Cosworth 4x4 gearbox where a guy had started off with similar symptoms. It had done a lot of damage to his car when it went. You rarely see anything about Cosworths in mainstream newspapers hence I remembered about it. The thread above is a similar issue ( I couldn't find any reference to the original Honest John article )

Not saying yours isn't something simple like the exhaust but it may be worth checking