Josh's Chassis Repair/Build - Nissan-Navara.net
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post #1 of 60 (permalink) Old 10-08-16, 12:21 AM Thread Starter
I'm now in 4th gear with power to spare!
 
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Post Josh's Chassis Repair/Build

Hey Guys,

So as some of you know I've recently bought an 06 King Cab Navara.

When I went to pick it up I travelled from Cornwall to Manchester, and had asked the seller specific questions thanks to research on this forum...

By the time we'd travelled up we had to wait for some one to meet us due to a 'Family Emergency' and was eventually met by a Family friend with a signed V5 Document and proof of recent M.O.T etc. Due to the delay the light was dark and being tired (and probably very naïve) my inspection of the truck was probably not as thorough as it should have been. I did get under the truck to have a look at the Chassis and saw surface rust which I was not surprised by at all, neither was I surprised to see the cross members with a little hole in it that needed repairing... so I crawled back out and carried on the rest of the inspection/test drive. There was a couple of niggling things that I haggled the guy down on but as I'd come nearly 400miles each way I decided to go ahead and buy the truck.

The drive home was eventless and I was stoked with it. We managed to pick up a King Cab topper Canopy on our route home which was a plus.

The next day we rested most of the day but did take the truck out to grab some food and a horrible squealing came from the engine.... Swung it by my father-in-laws on the way home to sort show him and get his advice (ex mechanic/mot tester and engineer) on squealing. Decided to investigating the next day and build some timber racking for tools in the back.

Upon investigation the intermittent squealing turned out to be the alternator which we assumed was either the belt or bearing.... after a bit of DW40 it stopped and didn't return. All mods went well and the next day was work. After towing the trailer for a few days the topper started banging against the truck cab so I slid it back a bit which stopped it. Again a day later the banging was back, worse than normal and it started squeaking permanently. I had it booked in to a garage to sort tracking out and told them of the noise when they enquired. They put it up on their lift with the wheels off and discovered two major cracks in the Chassis... one on each side....

I despaired and got in touch with Nissan that day and set up a claim and started doing in depth research in to processes and solutions.

Whilst I was waiting to hear from Nissan over the weekend I found some chassis strengthening plates and again consulted the Father-in-law and decided to buy them as an option should I need it.

Whilst gathering some more materials Nissan got back to me really quickly and the guy I spoke to was really helpful and told me the options frankly. He said in all likely hood if Nissan took responsibility they'd give me trade value £4k and that'd be it. Well I gave it some thought and decided that as I'd spent more than that for the truck and have investment in it already, plus I couldn't buy another king cab quickly for £4k we'd spend a day or two in the garage and strengthen her up ourselves.....

And that was the beginning of the saga....

So far its taken nearly £1000 in materials and 4 1/2 days of us trying to sort it out.... If I had to pay a garage it would have already cost as much if not more than I paid for the truck and would not be

I'm pleased to say we are almost there, we've had to replace most of the rear chassis from the back of the cab to the rear leaf spring mounts, cutting, jigging, welding and proofing as we go. The recent M.O.T was a joke as major Chassis failure, some one had recently wrapped a tea towel and zip tied it on because the rear near side half shaft seal had gone.... The seller who is selling several cars is refusing to respond and I found his family friends name on the M.O.T certificate from a garage just up the road where he lives... I have been in touch with C.A.B and have a plan of action and will keep you guys posted.... But this is a long text already and will let the pictures speak a few words....

Josh

2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!
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post #2 of 60 (permalink) Old 10-08-16, 12:27 AM Thread Starter
I'm now in 4th gear with power to spare!
 
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2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!
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post #3 of 60 (permalink) Old 10-08-16, 12:30 AM Thread Starter
I'm now in 4th gear with power to spare!
 
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2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!
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post #4 of 60 (permalink) Old 10-08-16, 12:42 AM Thread Starter
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Also found out that rear leaf spring was snapped, so replacing them tomorrow, replacing alternator, doing oil change, last welds air filter and putting the cleaned off fuel tank back on ready to fill again.

Future projects may include a small lift so I can fit chunkier tyres on, snorkel, and some form of lighting.

I'm undecided about a bull bar but wouldn't mind the idea of a bumper winch in time... it'd be usefull for work.

But for now I want to get the truck back on the road and lick my wounds....

Sorry this thread isn't as interesting as some but thought it may give an idea of what's involved in a chassis repair..... in hindsight I would have taken Nissan's offer sucked up the extra cost and put it down to life experience. But now I am too far in and will have the peace of mind of having a strong chassis. Just the timing belt niggling at my mind now.

2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!
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post #5 of 60 (permalink) Old 10-08-16, 03:25 AM
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Sorry to hear your truck has disappointed you, but top job so far. This is a level of work way beyond my skill so it's great seeing threads like this to learn stuff.
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post #6 of 60 (permalink) Old 10-08-16, 06:23 AM
Co1
I'm now in 4th gear with power to spare!
 
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Great job so far. Your obviously pretty handy so can we expect to see a build thread as you modify it?
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post #7 of 60 (permalink) Old 10-08-16, 08:03 AM
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Nice job so far, just a shame you didn't buy my plates as you would have had braces to go on the inside of the chassis too
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post #8 of 60 (permalink) Old 10-08-16, 09:14 AM Thread Starter
I'm now in 4th gear with power to spare!
 
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Originally Posted by Rich. View Post
Nice job so far, just a shame you didn't buy my plates as you would have had braces to go on the inside of the chassis too
Lookskyward told me about them just after I'd bought the others Rich. Gutted mate sorry.

Will keep an eye out for other bits you do. I don't want to turn it in to an off road monster but perhaps enhance its core capabilities.

2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!

Last edited by lookskyward1; 10-08-16 at 11:37 AM. Reason: you
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post #9 of 60 (permalink) Old 10-08-16, 09:19 AM Thread Starter
I'm now in 4th gear with power to spare!
 
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Quote:
Originally Posted by Co1 View Post
Great job so far. Your obviously pretty handy so can we expect to see a build thread as you modify it?
I've had huge amounts of help and let the welding be done by some one with far greater talent as it has to be just perfect on chassis....

I will keep you guys updated with any future mods etc

2006 Navara D40 manual basic model. 3" suspension lift and 285/75r17

Countrified, Bonafide, Worldwide, can say I've tried!

Last edited by lookskyward1; 10-08-16 at 11:37 AM. Reason: you
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post #10 of 60 (permalink) Old 10-08-16, 11:40 AM
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You took on a massive job there. It doesn't help that you were sold a dodgy truck in the first place, good luck with the rest of the rebuild and the trading standards claim.
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