Cheers lads. Just on top of sorting things at the moment, got some work shares I may be able to sell that will hopefully cover the repair bill. Looks like a new box is going to be the easiest way out of this and also the most cost effective. Once it's done, I think ill be down to Torque GT to look at trading in.
As I said to Mark on FB, I now understand how he lost his passion for his DC5 when it had been damaged. It kind of tarnishes your view of the car. Small things I can deal with, little niggles don't bother me, but something like this has made me want to take a match to the thing.
The most annoying part is Ford actually know about the issue. Lyns' dad has been in the garage I got it from this morning talking to one of their mechanics, and he stated there is an issue with the fifth gear in the gearbox. It basically shreds the bearing on the diff, which then gives up the ghost. This will either do one of two things, just stop fifth from working, or in the worst case, blow the bottom out of the box. There are some real horror stories out on the forums.
I'll keep you up to date on things, but hopefully it can get sorted quickly, and I can move on from this.