@murcod @smartguy69 Thanks your advice. Today my mechanic will refit the new transfer box once it arrives. He has measured and has about 12 threads available on a 10 threaded bolt, so we are hoping that will help with extra support. I have been in touch with head of ford and all they can say is that because i took it away from a ford dealership for repairs they cannot help me. I have told them that is because i dont have £8500 pounds for the repairs they wanted to charge me, on a car that is only worth now £8500. So absolutely no luck there. I am going to have to pay in 2k for early termination with my finance company, if i held onto it for 8 months i could just hand it back, but the repayments over 8 months work out the same, im just worried i keep it and next its the gearbox, complete replacement. I just feel that if Ford know about this issue they should have warned all dealerships when servicing and MOT to check these bolts, it was clearly visible when taking the bottom tray! Will update you with how we get on. Any further suggestions are most welcome. I might have to replace the propshaft too, but we hoping that there is limited damage on that, i think ive sourced a second hand one for now incase, else thats another £800 from ford. I looking at Kia as a replacement, i see they also have AWD any advice?