Known for its incredible off-road ability and some great safety features, the Nissan Navara D40 is a popular choice for truck enthusiasts the world over. But like all other car models, the D40 series does experience some common faults. 

In this article, we’re going to look at the Nissan Navara D40 Common Problems and what you’ll need to do to fix them. 

To add to this, we also intend to discuss the recalls surrounding this vehicle. Recalls happen when the manufacturer detects a vehicle defect that poses a risk to users.

D40 4×4 Series (2004-Present)

Within the four generations of Nissan Navara pickups lies a subset code name D40. This pickup truck superseded the D22 (1997 – 2004) and was first introduced at the North American International Auto Show in 2004. 

Initially, only dual-cab Navara models were available. In 2008 however, a king-cab (with rear doors that open forward and a tiny rear perch) became available.

This vehicle circulates the North American markets as the Frontier, whilst it is referred to as Navara in Europe and Australia. Some markets also badge it as Navara Brute, Nissan Equator, and a few more different names.

The Nissan Navara D40 utility truck has two engines in the market: 

• The most common type is the 2.5-liter turbocharged diesel engine (128kW of power, 403 N.m of torque)
• For the non-diesel kind of people, Nissan made a 4.0-liter V6 petrol engine (198kW of power, 385 N.m of torque)

Both engine types were equipped with a five-speed automatic transmission or six-speed manual gearbox. 

In 2010, things got real after Nissan launched the 3.0-liter V6 turbo-diesel as part of the D40 series. Now, there was a monster engine type with a power of 170kW and 550 Nm of torque. 

This would later power the top-tier Pathfinder shortly after. The V6 diesel was only equipped with a seven-speed automatic transmission. 

While some models are equipped with leather, satellite navigation, or climate control system, these models are only available in some markets like the U.K. 

6 Common Nissan Navara D40 Faults

1) Timing Chain Stretch

The 2.5-liter YD25DDTi turbo-diesel engine in the Nissan Navara D40 can have: 

• A simplex (single row) primary timing chain and gears
• A duplex (double row) secondary timing chain and gears

The single-row timing chain has been reported to stretch, as have the timing chain guides and vacuum pump timing chain sprocket and shaft. This may cause wear and show signs of damages in timing chains.

If the timing chain breaks apart, the pistons and valves are likely to collide, thus causing severe engine damage that requires a rebuild or replacement. Premature wear that the chains suffer is a result of this fault. 

Before reaching 80,000 km, it is recommended you replace the single-row timing chain and tensioners and inspect every 40,000 km thereafter. 

For enhanced longevity, double-row timing chain kits have been created and may prevent single-row timing chain failure.

2) Cracked Firewall: Clutch Not Engaging

A cracked firewall is a common problem with commercial vehicles. However, the Nissan D40 Navara is said to be particularly prone to this problem due to the forces applied to the firewall, usually when the vehicle’s body flexes.

Because of these cracks, the clutch may end up not engaging.

3) Exhaust Gas Temperature Sensor Failure

In August 2013, Nissan Australia launched a maintenance program for 2012 and 2013 Nissan D40 Navara vehicles with 2.5-liter diesel engines. 

The EGT sensor on these cars had a high rate of failure, often putting the engine into “limp home” mode to help prevent turbocharger overheating–which is why it was replaced.

The ‘limp home’ mode restricts the power output of the engine, limiting the speed to around 2000 rpm. An oxygen sensor failure that causes a failed exhaust gas temperature sensor will also give the P0546 DTC error code (DTC).

To solve this problem, the EGT sensors were replaced with new versions distinguished by a ‘B’ suffix on their part number. The sensor was then installed behind the exhaust manifold, close to where the turbocharger is connected.

4) Driveline Vibrations And Prop-Shaft Universal Joint

Driveline vibrations can likely result from wheel problems or prop-shaft universal joints in the case of Nissan D40 Navara; or the torque converter for the automatic models. 

In April 2010, Nissan North America published a Nissan Technical Bulletin NTB 10-052 for the R51 Pathfinder vehicles and the Nissan D40 Navara/Frontier equipped with a propeller shaft universal joint (u-joint) that produces noise or vibration.

The service bulletin stated that it was possible to determine the universal joint as the source of noise or vibration by removing and testing the propeller shaft to see whether:

• The axial play or flex effort of the universal joint was greater than the requirements in the ESM (Electronic Service Manual).
• There was a jerky feel during rotation.

In both instances, the universal joint was subject to replacement.

5) Coolant Leak From The Exhaust Gas Recirculation (EGR) Cooler

The EGR cooler on the Nissan Navara D40 YD25DDTi may experience internal corrosion or cracking, resulting in a coolant leak. 

The coolant may evaporate as a result of the heat from the exhaust system, making it difficult to detect any pooling beneath the truck.

Due to this, check your car’s coolant level on a regular basis and look for stains around the EGR pipe and cooler. If your coolant loses too much fluid, your vehicle’s engine will overheat—leading to failure of the cylinder head gasket.

6) Front Suspension Noises

It’s common for Nissan D40 owners to encounter a clunking, squeaking, or popping noise when going around hard corners or full lock on the steering wheel. This can be caused when the bushings in the shock absorbers become very old, worn-out, and tight against the bolts, causing the bushings to bind up.

The simplest way to fix any suspension issues in the front of the Nissan Navara is to purchase a high-quality aftermarket bushings kit for the front end and get it fitted by your local mechanic. The cost for the replacement (including labor) will set you back between $200 to $300.

Now, let us take a look at some of the most frequently asked questions (FAQs) about the Nissan Navara D40.

Recalls: Nissan Navara D40 

Even with the most advanced cars like Porsche and other models, recalls are inevitable. And just like them, the Nissan Navara D40 has also been subject to recalls. 

As such, it’s always critical to double-check that all necessary recalls have been completed—regardless of whether you’re purchasing a new or used vehicle. 

Here is a list of recall work issued for the Nissan Navara D40 since 2006:

Steering Shaft – Recalled in February 2006

This recall was issued for improper fitting of the lower steering shaft. The defect was that the shaft could break or become detached—resulting in steering failure. 

Rear-Wheel Bearing Issue – Recall between May and Aug 2006

In May, July, and August 2006, Nissan D40 Navara vehicles received recalls due to the potential for excessive wear of the rear wheel bearings. 

If ignored, the wheel bearings could have failed, causing the shaft assembly to detach from the axle. 

Braking Performance For Non-ABS-Equipped D40s – Recalled in October 2006

In October 2006, a recall was issued for non-ABS-equipped D40s. The ABS relay box bracket for vehicles with ABS specification was also added in non-ABS vehicles. 

If the relay box bracket had made contact with the rear brake pipe in the engine compartment, this could have negatively impacted braking performance.

Bonnet May Open While Driving – Recalled in May 2010

It took a few years for the Nissan D40 pickup to issue another recall since its last recall. This time, a common Nissan Navara D40 fault was the bonnet. 

Vibrations generated from outback travels were causing the bonnet latch to break, thus flipping up unexpectedly while driving.

Engine May Stall And Not Restart – Recalled in October 2010

A recall for 2005-2006 D40s was issued in October 2010 because of engine problems, including a faulty ignition relay box that might become clogged with silicon dioxide and prevent the contacts from functioning. 

As a result, this caused the engine to stall and fail to restart.

Nissan D40 Navara Dual Cab ST-X: Alloy Wheel Spokes May Crack – Recalled in May 2011

A recall was called for the D40 ST-X in 2011 because of the risk of alloy wheels on dual-cab ST-X variants produced between 2005 and 2008. 

If unaddressed, the wheel may detach or come off, posing a serious risk to users and motorists.

Towbar: Chassis Frame Rail Crack – Recalled in April 2013

The recall was prompted by an April 2013 announcement for cars manufactured between 2005 and 2010, including genuine add-on towbars.

It was determined that the towbar’s attachment points could, over time, put too much strain on the chassis frame rails. This might result in fractures or bends in the chassis rails around the towing point.

Seatbelts Swap – Recalled in December 2013

In December 2013, D40 Navara vehicles were recalled because the left and right seatbelts on the driver’s side may have been switched. 

This fault might influence restraint effectiveness in a collision and pose a significant risk of injury to passengers.

The Inflator Housing Of The Airbag May Burst – Recalled in March 2016

Navara was also affected by the Takata airbag recall, which began in March 2016 and covered vehicles built from 2008 through 2014.

In these trucks, moisture may collect over time in the propellant tablets of some airbag inflators. 

This might cause the inflator to burst under high internal pressure when the airbag is deployed, causing metal shards to scatter and putting passengers at risk.

Extended ball joints (Performance Suspension) – Recalled in May 2016

In May 2016, Performance Suspension issued a recall for extended ball joints produced for the Nissan D40 Navara. 

In some instances, the ball joints would fail. If the vehicle’s suspension fails while it is in motion, the wheels may fall off, posing a safety hazard to the passengers and other road users.

FAQs

Are Nissan Navara D40 reliable?

Generally, the D40 series is often a robust and reliable truck. However, the clutch appears to have repeated issues with some users reporting that they had to replace the clutches more than inside 100,000 kilometers.

What are the most common problems with Nissan Navara?

Some common faults with Nissan Navara include timing chain stretch, oil pump issues, manifold crack, front suspension noise, cracked firewall, driveline vibrations, stalling battery, EGT sensor entering the limp mode, and coolant leak, among others. 

What year did Nissan Navara have chassis problems?

Nissan produced a large number of its Navara range between 2005 and 2015, during which time there were reports of steering problems. 

So, contrary to popular belief, the problems affected not only the current Nissan NP300 Navara (sold in 2016), but also the previous Navara models.

How many kms will a Nissan Navara last?

The D40 Navara is not regarded as a long-term investment prospect by most people, and many in the business believe that 160,000 kilometers remain the maximum mileage.

Conclusion

The Nissan Navara D40 Series is a popular choice for those who want to save money but still get the best of what the world has to offer. With all-wheel drive and V6 engine options, it’s hard not to appreciate this rig!

But with the above-listed common faults, it can be difficult to know how you should address them. We hope that this article has been insightful, and if you find your truck experiencing some of these problems, don’t hesitate to reach out to a mechanic for a proper diagnosis.