The clutch actuator on the side of the gear box has a cover-plate to protect the mechanism from mud and stones. There are two brackets at the front of this cover that frequently break due to vibration. I have not seen any Daily 4x4s without these brackets broken! Once broken they can make an annoying rattling sound while the engine is idling, so I wanted to find a solution.
First, I simply re-welded the brackets to see how long they would last. Answer: less than 10,000 km! Next I was tempted to simply change the brackets for ones made of thicker material, but I was concerned that this would potentially move the problem onto the next weakest component and then that would fail. I therefore decided to fit anti-vibration bushes. These bushes should provide the cover with the support it needs, but hopefully also allow for some vibration without overloading the brackets.
And now with the anti-vibration bushes installed:-
And installed:-
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