Hi Ian,
I don't think anyone will be able to give you a definitive answer here.
For what it's worth I think the RAC are right. A carnet does not cease to have effect when it's expiry date is up (otherwise no-one would worry very much about claims ;-). Plus if you are in possession of a new one then the continuity is clear.
However that doesn't mean that a customs official won't refuse to stamp a document which is out of date. He may think it's the correct approach (a fair enough assumption) or he may just be glad of a reason to inject a little interest into an otherwise boring day.
If it were anywhere other than a SACU country I would be very relaxed about it as the chances are no-one will even look at the date. However, I understand that SACU are responsible for by far the majority of unclosed RAC carnets. In other words if you don't get it stamped out for whatever reason then it may be difficult to get your release notwithstanding other evidence (eg subsequent carnet entries and exits and even the presence of the car back in the UK).
In short you need to make a decision whether you want to risk it or play it safe.
Perhaps ask the RAC if they would consider doing you a letter to show at the border (only if the issue arises - don't bring it up yourself) saying that you have replaced your carnet whilst overseas and could the customs official please ensure that the exit stamp is on the same document as the entry stamp notwithstanding the date on the document. I suggest you draft the letter for them and ask if they will have it put on their headed notepaper and signed. They may say no but it would be worth a try. "Official" letters carry a lot of weight at African borders.
Best of luck.
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