Recalls & faults: Nissan D40 Navara utility (2005-14)

Recalls: Nissan D40 Navara utility

Overview

Manufacturers, or importers, issue recalls for defects or faults which have the potential to cause injury. Generally, manufacturers will inform the original buyers if their vehicle is subject to a recall and of the steps required to remedy the defect or fault. Please note that the recalls below (if any) are for Australian-delivered vehicles only. Furthermore, the number of recalls should not be taken as an indication of a model’s reliability or its safety more generally.

Recalls: Nissan D40 Navara utility

Nissan D40 Navara: steering shaft may detach

In February 2006, a recall was issued for Nissan D40 Navara utilities due to problems with the fitment of the lower steering shaft which could result in the shaft becoming detached a loss of steering control (PRA 2006/8355). The recalled D40 Navara vehicles had VINs in the following ranges:

• VSKCLAD40A0025460 to VSKCLAD40A0069158;
• VSKCLND40A0033906 to VSKCLND40A0069215; and,
• VSKCVND40A0025461 to VSKCVND40A0069400.

Nissan D40 Navara: rear wheel bearing wear

In May 2006 (PRA 2006/8534), July 2006 (PRA 2006/8636) and August 2006 (PRA 2006/8713), recalls were issued for Nissan D40 Navara vehicles due to the potential for excessive wear of the rear wheel bearings. Initially, this wear could lead to noise from the rear axle. If not rectified, however, the bearings could fail and cause the half shaft assembly to become detached from the axle. From the July 2006 notice, the recalled vehicles had VINs in the following ranges:

• VSKCLAD40A0025460 to VSKCLAD40A0053741;
• VSKCLND40A0033906 to VSKCLND40A0055143;
• VSKCLND40A0900600;
• VSKCVND40A0025461 to VSKCVND40A0055115; and,
• VSKCVND40A0900655.

Nissan D40 Navara without ABS: braking performance

In October 2006, a recall was issued for Nissan D40 Navara vehicles without ABS (PRA 2006/8847). In the affected vehicles, the relay box bracket for vehicles with ABS specification was assembled in non-ABS vehicles – this could result in interference between the relay box bracket and a rear brake pipe in the engine compartment which could affect braking performance.

Nissan D40 Navara: ID plate incorrectly stamped

In May 2007, a recall was issued for Nissan D40 Navara utilities due to the ID plate on the left B-pillar potentially having been stamped with the wrong approval (CPA) number (PRA 2007/9299).

Nissan D40 Navara: bonnet may open while driving

In May 2010, a recall was issued for Nissan D40 Navara utilities due to vibrations potentially causing the hood striker loop to separate from the hood and damage the hood latch assembly (PRA 2010/11664). As a result, the hood may not be securely latched and could open unexpectedly while driving. The affected vehicles were in the following VIN ranges:

• VSKCLAD40A0025460 to VSKCLAD40A0366783; and,
• VSKCLND40A0033906 to VSKCLND40A0369626.

2005-06 Nissan D40 Navara: engine may stall and not restart

In October 2010, a recall was issued for Nissan D40 Navara utilities available for sale prior to 28 June 2006 (PRA 2010/12094). In these vehicles, the ignition relay contacts within the power distribution module could become contaminated with a build-up of silicon dioxide and cause poor conduction at the relay contacts. At worst, this poor contact could result in the engine stalling and failing to restart. The recalled Nissan D40 Navara vehicles had VINs in the following ranges, though not all such vehicles were affected:

• VSKCLAD40A0025460 to VSKCLAD40A0119258; and,
• VSKCLND40A0033906 to VSKCLND40A0118785.

Nissan D40 Navara Dual Cab ST-X: alloy wheel spokes may crack

In May 2011, a recall was issued for dual cab Nissan Navara ST-X variants sold from 1 June 2005 to 3 July 2008 (PRA 2011/12582). In these vehicles, cornering with high lateral acceleration under full load conditions could cause cracking in the alloy wheel spokes. In the vehicle continued to be driven, the crack may spread around the wheel spokes and affect handling. If ignored, the wheel could detach in extreme cases. The recalled Nissan D40 Navara Dual Cab ST-X vehicles had VINs in the following ranges:

• VSKCLAD40A0025460 to VSKCLAD40A0335424;
• VSKCLND40A0033906 to VSKCLND40A0900600; and,
• VSKCVND40A0025461 toVSKCVND40A0901091.

2005-10 Nissan D40 Navara towbars: chassis frame rails may crack

In April 2013, a recall was issued for Nissan D40 Navara utilities that were fitted with Nissan genuine accessory towbars and available for sale from 1 July 2005 to 30 January 2010. Over time, the attachment points on the towbars could exert excessive stress upon the chassis frame rails and cause cracks at the end of the rails. In extreme cases, sections of the chassis rails around the towbar attachment points may bend when a heavy load is applied (PRA 2013/13559). The affected vehicles were in the following VIN ranges:

• VSKCLAD40A0025460 to VSKCLAD40A00366783;
• VSKCLND40A0033906 to VSKCLND40A0369626; and,
• VSKCVND40A0025461 to VSKCVND40A0369632.

Nissan D40 Navara: seatbelts may have been swapped

In December 2013, a recall was issued for D40 Navara vehicles because the left and right side seatbelts may have been swapped. In the event of a collision, this defect could affect restraint performance and present a serious risk of injury to the occupants (PRA 2013/13891).

Nissan D40 Navara: airbag inflator housing may rupture

In March 2016, a recall was issued for Nissan D40 Navara vehicles that were manufactured in Thailand between 2008 and 2014. In these vehicles, propellant tablets in some of the airbag inflators may absorb moisture over time. This could create excessive internal pressure on deployment of the air bag such that the inflator could rupture, causing metal fragments to scatter and pose a hazard to the occupants of the vehicle. The recalled Nissan D40 Navara vehicles had VINs in the range MNT*C*D40A0000009 to MNT*C*D40A0603279 (PRA 2016/15228).

Nissan D40 Navara extended ball joints (Performance Suspension)

In May 2016, a recall was issued for extended ball joints that were produced by Performance Suspension for the Nissan D40 Navara. The ball joints could fail in some circumstances, causing separation of the ball joint components; if this occurred while the vehicle was being driven, the separation of the ball joint would cause the suspension to fail, posing a serious safety hazard to vehicle occupants and other road users. The Performance Suspension ball joints were available for sale from 17 April 2015 to 9 May 2016; consumers should immediately stop using the ball joints and contact Performance Suspension for replacement ball joints or a full refund (PRA 2016/15375).

Search online for recalls by VIN

To see if a Nissan vehicle has been recalled due to the fitment of Takata airbags, you can conduct a search on the Nissan Australia website using its VIN.

Problems and faults: Nissan D40 Navara utility

Overview

This section identifies potential problems, causes and fixes based on the experiences of owners and repairers, online sources and technical service bulletins. This information is provided solely for reference purposes and AustralianCar.Reviews recommends that only properly qualified persons carry out repairs or modifications. Furthermore, the number of items below should not be taken as an indicator of a model’s reliability or the frequency with which they may occur.

To report a problem or fault to the AustralianCar.Reviews team, please use the Contact Us form. Note that AustralianCar.Reviews does not offer advice on automotive problems or disputes; such enquiries will not receive a reply. For vehicles purchased from dealers after 1 January 2011, please see our Australian Consumer Law fact sheet.

Nissan D40 Navara: YD25 timing chain failure

For the Nissan D40 Navara, the 2.5-litre YD25DDTi turbo-diesel engine has:

• A simplex (i.e. single row) primary (lower) timing chain and gears; and,
• A duplex (i.e. double row) secondary (upper) timing chain and gears.

For the primary simplex timing chain, there have been reports of the timing chain stretching, while the timing chain guides and the vacuum pump timing chain sprocket and shaft may also exhibit wear and/or damage. If the timing chain stretches, the valves and pistons can collide and cause serious engine damage such that the engine has to be rebuilt or replaced.

It is recommended that the simplex timing chain and tensioners be replaced before 80,000 kilometres and inspected every 40,000 kilometres thereafter. Due to the premature wear and failure of the single-row timing chains, aftermarket double-row timing chain kits have been developed for greater longevity.

Nissan D40 Navara with YD25DDTi diesel engine: coolant leak from EGR cooler

For Nissan D40 Navara vehicles with the 2.5-litre YD25DDTi diesel engine, the Exhaust Gas Recirculation (EGR) cooler may corrode or split internally or around its flanged ends, causing a coolant leak. Due to the heat of the exhaust system, the coolant may evaporate and therefore not be seen pooling beneath the vehicle. As such, signs of a leaking EGR cooler are:

• A low coolant level; and,
• Coolant stains around the EGR pipe and cooler.

If not repaired, the loss of coolant could cause the engine to overheat and damage the cylinder head gasket. While some have sought to rectify this problem by bypassing the EGR system, this is not recommended because the vehicle will not comply with emissions standards and will be unroadworthy.

Nissan D40 Navara: cracked firewall

There have been multiple reports of Nissan D40 Navara vehicles experiencing cracks in the firewall around the clutch master cylinder, which prevents the clutch from engaging. While this problem is not uncommon in commercial utilities, the Nissan D40 Navara seems particularly susceptible due to the forces exerted on the firewall when the body flexes.

Nissan D40 Navara V6: buzzing noise from timing chains

In November 2009, Nissan USA service bulletin NTB09-128 for 2005-10 Nissan D40 Navara/Frontier vehicles with the 4.0-litre VQ40 V6 petrol engine. In these vehicles, there may be a high frequency buzzing/whining noise from the secondary timing chain system that increases in frequency with engine speed (rpm).

To fix, both secondary timing chains and both secondary timing chain tensioner ‘shoes’ were to be replaced; the engine oil and filter were also to be changed.

Nissan D40 Navara: exhaust gas temperature sensor failure

In August 2013, Nissan Australian initiated a service campaign for 2012 and 2013 Nissan D40 Navara vehicles that had 2.5-litre diesel engines. For these vehicles, the exhaust gas temperature sensor had a high failure rate and could cause the engine to enter into ‘limp home’ mode to prevent possible overheating of the turbocharger. In ‘limp home’ mode engine speed would be limited to around 2000 rpm and power output would be restricted; a failed exhaust gas temperature sensor would also result in the P0546 diagnostic trouble code (DTC) being logged. Revised exhaust gas temperature sensors were released – these were distinguished by their part number having a ‘B’ suffix. The exhaust gas temperature sensor was fitted to the back of the exhaust manifold where the turbocharger was connected.

Nissan D40 Navara: driveline vibrations and prop-shaft universal joint

For the Nissan D40 Navara, driveline vibrations may be attributable to wheel problems, prop-shaft universal joints or, for automatic models, the torque converter (particularly from 80-100 km/h, described below).

In April 2010, Nissan North America issued Nissan Technical Bulletin NTB10-052 for Nissan D40 Frontier/Navara and R51 Pathfinder vehicles due to noise and/or vibration from the propeller shaft universal joint (u-joint). According to the service bulletin, the universal joint could be identified as the source of the noise and/or vibration by removing the propeller shaft and testing to see if:

• Universal joint axial play or flex effort exceeded the specifications in the Electronic Service Manual (ESM); or,
• If a ‘ratchety’ feel was exhibited during rotation.

In either case, the universal joint was to be replaced.

Nissan D40 Navara auto: driveline vibration from torque converter

For Nissan D40 Navara vehicles with automatic transmissions, owners have reported experiencing shuddering/vibrations in the following conditions:

• Driving at speeds between 80 km/h and 110 km/h;
• Overdrive (O/D) is engaged; and,
• When there is a load on the transmission (i.e. accelerating for a hill or overtaking).

Generally, the shuddering is accompanied by engine rpm dropping by around 5000 rpm. It is understood that the shuddering/vibration is caused by the torque converter clutch (TCC) solenoid not engaging properly (i.e. continually engaging and disengaging). To fix, the torque converter has to be replaced.

For reference, the Torque Converter Clutch (TCC) solenoid is supposed to close when the following conditions are satisfied:

• Overdrive is engaged;
• The gear selector is in ‘Drive’;
• The transmission has engaged 5th gear;
• Throttle position is less than 50 per cent; and,
• Vehicle speed is 75km/h or higher.

Furthermore, any of the following conditions causes the TCC to disengage:

• Vehicle speed drops below 75 km/h;
• Throttle input exceeds per cent;
• Overdrive is disengaged; or,
• The gear selector is moved out of Drive.

Nissan D40 Navara: front suspension noise and stabiliser bar bushing

In October 2010, Nissan North America issued Nissan Technical Bulletin NTB10-072a for Nissan D40 Frontier/Navara and R51 Pathfinder vehicles due to a noise (clunking, squeaking or popping) that could be heard from the front suspension when performing at least one of the following actions:

• Turning the steering wheel left or right;
• Driving over speed bumps;
• Driving on rough roads; or,
• Accelerating or decelerating.

According to the service bulletin, the noise was attributable to wear of the front stabiliser bar bushing or bushings.

To fix, the front stabiliser bar bushing on both sides were to be replaced. Prior to installing the new bushings, the service bulletin stated that a brake cleaner should be used to clean the stabiliser bar where it made contact with the bushings.

Nissan D40 Navara: seatback vibration at highway speeds

In June 2008, Nissan North America issued Nissan Technical Bulletin NTB08-063 for 2007-08 Nissan D40 Frontier/Navara and R51 Pathfinder vehicles because the right front seatback may vibrate when the vehicle is driven at highway speeds.

While the repair procedure differed according to whether the vehicle had a soft seatback board or a hard seatback board, the repair required the following steps:

• Removal of the seatback board;
• Application of foam tape to a mass (vibration) damper and installation of the damper;
• Cutting the J-clip on the seatback to assure free movement of the mass damper; and,
• Re-assembly of the seatback.

Nissan D40 Navara utility: Other problems and faults

• For Nissan D40 Navara utilities with petrol engines, a chirping noise from the engine – particularly on start-up – is likely to be the drive belt slipping. If so, a new drive belt and tensioner is required.
• For Nissan D40 Navara utilities with the 4.0-litre V6 engine, a rattling noise around 2000rpm is likely to be the power valve actuator – this can only be fixed by replacing the manifold (which includes the valve).
• For models with turbo-diesel engines, a metallic rattling noise after start-up may be due to a worn or partially blocked injector jet – this may be fixed by using fuel additives, though the injector may require replacing.
•  For early models, there have been reports of clutch failure which has been preceded by clutch slippage accompanied by a burning smell. Later models were fitted with an uprated clutch, flywheel and pedal box.
• On models with automatic transmissions, the heat exchanger inside the radiator may fracture, leading to the automatic transmission fluid becoming contaminated and causing the transmission to fail.
• The four-wheel drive light on the dashboard may stay on permanently due to a faulty switch, possibly caused by moisture in the switch.
• A squeaking noise from under the bonnet may be due to the bonnet catch rubbing or the rubber buffer squeaking – this can be fixed by applying general purpose grease on the catch and buffers.
• The power windows may stop working if the battery is disconnected or if the window fuse blows – if so, the windows require reprogramming.
• If the manual seats cannot be adjusted fore and aft, the linkage may have separated and require replacement.