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Old 29 November 2016, 06:41   #1
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Navara D40 - Check your chassis

I thought I might share the issues we've had with our Navara D40 in the hope that people will check their chassis and potentially avoid catastrophic failure.

Our Navara is a 55 plate outlaw. Its done about 60k and has spent most of its life doing the short daily commute to work (at a school). It occasionally tows the boat and sometimes a horse box, but no more than 10 trips a year. I've never had to dunk it to launch or recover. It has done about 4 hours off road in its life and has always been serviced at Nissan, when scheduled.

Last year it failed its MOT on the front and rear suspension mounts due to rust. We also had to have a plate welded on the chassis by the fuel tank as the old had vanished, as had one of the fuel tank straps. In August we noticed that the passenger side front mount for the rear spring was also disappearing so booked it in to be welded again. Before we got that far, we noticed a hole in the chassis member, just in front of the front left bed mount. A quick poke with a finger revealed that the hole was actually quite large and a crack had formed down to the bottom of the chassis section. The underside had a 5cm by 1cm section missing in the same location. A piece of 3mm thick "metal" that fell out of the hole could be snapped easily by hand. The long and short of it is that our chassis is rusted to hell, from the inside out, and is no longer roadworthy. It could be plated I guess but I have no confidence that the surrounding metal is any better.

By chance we had heard of other issues and found a facebook group devoted to the issue as this is not an isolated case. We contacted Nissan, who now have a team set up specifically to deal with rusty Navaras, and they sent somebody to inspect. Sure enough, it has been condemned and Nissan are in the process of buying it back from us, at actually a good market rate. We have been offered a reasonable discount on a new Navara instead but have declined as we just don't like it.

So, if you have a D40, please please check the chassis for rust, particularly around the suspension mounts and bed mounts. I don't know which years were affected (although 55 plate is) but if you have any concerns, contact Nissan and they will inspect it.

Now all we are waiting for is VW to release the Amarok V6 price list and we can get it replaced.

Phil M
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Old 29 November 2016, 07:27   #2
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sounds like a lucky escape Phil it could have failed on you big style hope you get sorted with the VW
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Old 29 November 2016, 09:23   #3
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I know it doesn't help, but well documented on Nissan-navara.net
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Old 29 November 2016, 13:10   #4
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I was in a local dismantlers recently buying a fiesta door and they had about 30 navaras lined up they buy them direct from nissans insurance.interestingly they said there starting to get pathfinders for the same chassis issue too
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Old 29 November 2016, 14:43   #5
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https://www.facebook.com/groups/505526562959686/ go here... I have a Navara luckily mine is ok... Nissan inspected it... other owners are not as lucky...
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Old 29 November 2016, 16:40   #6
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Had a 56 Plate Merc ML320....not as bad as that but definitely going the same way
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Old 30 November 2016, 07:26   #7
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The Amarok price list finally came out this or last week. Only the auto available at the moment. The missus wanted the manual but should be easily convinced. Not cheap but a gorgeous vehicle. We'll be checking and possibly upgrading the under body seal when it arrives.

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Old 30 November 2016, 14:52   #8
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is that with the asthmatic twin turbo 2.0 tdi iv a friend bought one and he seriously regrets it wishes he bought a ranger
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Old 30 November 2016, 14:58   #9
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No its a 224hp 3 litre V6. I had a toureg as a courtesy car with the same engine for a week or so a while back and it was really quite impressive. The 2l twin turbo is not being continued.

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Old 30 November 2016, 15:42   #10
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that's good iv also had a 3.0 tdi touareg and the v6 is superb
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