D40 Chassis rust

lookskyward1 · May 22, 2015

I received this PM from Dave at Billcar looking for information

billcar said:
Hi,

As you might of heard or maybe its already posted there seems to be some Navara chassis problems corroding cracking/breaking, I have been in contact with Nissan & we are in need of the below information.

Reg Numbers,
chassis Numbers
Mileages
Photo’s

Maybe you could set up post, or through a pm they could email us direct.
I do understand that not everyone wishes to post the data of vehicle online.

Kind Regards Dave
Email, engineering@billcar.co.uk

I would appreciate if the basic information is also shared here even if it is just vehicle age/mileage and some pictures.

lookskyward1 · May 22, 2015

Two I am aware of;

viewtopic.php?f=10&t=99306&hilit=chassis+rust

viewtopic.php?f=14&t=104050&hilit=chassis+rust

lookskyward1 · May 22, 2015

Dave tells me he is aware of 15-20 vehicles with failed chassis already :shock:

I've PMed Gramas and Chassmash

Hamlet · May 22, 2015

Although I realise he probably won't be able to do much with info from Ireland I'll send him on my details on this anyway.

I was taking to the guy who does my DOE's (MOT) when I was getting the D22 done and he says he sees loads of D40's coming in with this problem, always in the same place, passengers side, outside of the chassis leg, just behind the forward tub mounting point. Starts off as corrosion, ends in a crack, mine is just about going from the corrosion stage and will need to be plated.

They have no problem signing off a chassis like this as long as it has been properly plated along with an engineers report which they can provide.

My theory on this, poor materials used in initial construction, poor or complete lack of protection applied to the chassis after construction, and perhaps the cause of failure in this area might be it's exposed location to debris etc. thrown up by the rear wheel. Most puddles, mud, stones etc. are located in this area of roads.

On my truck the chassis is generally in good repair, this area on the drivers side is perfect, and the inside of the chassis on the passengers side where the crack is developing is in good condition.

It would be interesting to see if left hand drive trucks are having this problem on the opposite side.

chassmash · May 23, 2015

Hi Chassmash here.
Will post the details to Dave at billcar as mine has just failed the mot even though it has had some welding there now seems to be an issue where the leaf spring meets the chassis more corrosion its a 2006 and I am gutted ..............

Hamlet · May 24, 2015

I see that this has now become such a problem in Ireland that people are now advertising repairs, Nissan Navara specific.....

http://cars.donedeal.ie/cars-for-sale/nissan-navara-chassis-damage-buy-or-repair/9485538?offset=1

nexsuperne · May 24, 2015

What's the plan? Are we going to start a mass lawsuit against Nissan for doing a **** poor job?

greenster918 · May 28, 2015

The garage I use had a Nav in last week with a snapped chassis.

My truck is due it's mot in next few weeks so keeping everything crossed that things look ok

Bertie B · May 30, 2015

Hi Guys.
Should we Pathfinder owners be looking at this seriously???

BertieB

lookskyward1 · May 30, 2015

I don't think there is as much a chance of the Pathfinder snapping in half lile some of the Navaras have been however the rust itself is likely to be just as much an issue. Well worth getting the underseal done :nailbiting

One known issue the Pathfinder does have, is the alloy coolant pipes that run to the rear of the truck, these corrode and will cost a fortune to replace. Worth inspecting and getting some coating on. :fingersx

Bertie B · May 30, 2015

Many thanks for the info.

carlstoke · Jul 8, 2015

I cleaned all my chassis up mine was pretty rusty but nothing major and that's on a 56 plate if that helps there was no cracks or really bad corrosion

BrenGun · Jul 17, 2015

Just this last weekend been underneath my 56 plate nav. All now cleaned off and under sealed again and looked ok. Will see come mot time though.

The Dug · Jul 17, 2015

I'm planning on getting a full waxoyl under seal once I've had the duplex done, is that a smart move or should I be getting something else done first?

magicbeard · Jul 30, 2015

lookskyward1 said:
I received this PM from Dave at Billcar looking for information

billcar said:

Hi,

As you might of heard or maybe its already posted there seems to be some Navara chassis problems corroding cracking/breaking, I have been in contact with Nissan & we are in need of the below information.

Reg Numbers,
chassis Numbers
Mileages
Photo’s

Maybe you could set up post, or through a pm they could email us direct.
I do understand that not everyone wishes to post the data of vehicle online.

Kind Regards Dave
Email, engineering@billcar.co.uk

Click to expand...

I would appreciate if the basic information is also shared here even if it is just vehicle age/mileage and some pictures.

What was the response from Nissan GB on this issue ?

magicbeard · Jul 30, 2015

Here are some pics of my 55 plate D40 N/S rear chassis leg. The milage is 220K , never been in water, tow a caravan 2 times a year. Never overloaded, Never been off road. Owned it from new. Factory fitted Towbar.

The ratchet strap is holding the fuel tank on. The fuel tank bracket fell off due to corrosion which is how I spotted the cracked chassis.

Has anyone been in contact with Nissan GB about this growing trend in broken chassis?

I see the Spanish built Nissans from 05/06 were recalled in Australia with chassis defects. Why were the UK versions not recalled too ?

lookskyward1 · Jul 30, 2015

Hi Magicbeard,

Any results will be reported here, so the answer is there is no further news on the matter.

It would be appreciated if you contact Billcar with the information as requested in my previous post.

I take it you don't fancy doing a chassis swap or repair?

magicbeard · Jul 31, 2015

OK, will do.

I have been in contact with Nissan GB about this and the vehicle has been to my local dealership for a technical assessment. I am waiting on the outcome from Nissan GB before deciding what to do.

Cheers

magicbeard · Aug 13, 2015

Finally got a reply from Nissan GB Customer services. Their spokeswoman told me that the chassis is not considered to be an integral part of the vehicle so they would not honour the 12 year anti corrosion warranty.

So for Navara D40 owners with rusted chassis rails , your wonderful 12 year anti corrosion warranty is not worth the paper it's printed on.

My chassis is so badly rusted , the garage are unable to weld it as there is nothing left to weld too. The corrossion from the inside out has spread over most of the rear chassis rails.

magicbeard · Aug 13, 2015

Nissan GB told me they were not aware of any other Navara D40 models suffering from corrosion issues in the chassis or chassis stress cracks.

I find this hard to believe as there are lots of reports on this forum and all over the internet

Has nobody contacted Nissan about this issues before or are Nissan GB lying ?

lookskyward1 · Aug 13, 2015

Read Billcar's message in my first post.

magicbeard · Aug 13, 2015

Been in contact with Billcar already. However , I'm not entirely clear what their motivation is for collating data on the D40 chassis problems.

Nissan GB claim they have not received any complains from D40 owners in the UK concerning Chassis Corrosion or Chassis Cracks.

Bit puzzled really ?

lookskyward1 · Aug 13, 2015

magicbeard said:
Been in contact with Billcar already. However , I'm not entirely clear what their motivation is for collating data on the D40 chassis problems.

It is an interesting question. It will be extremely difficult to get a true picture of how many D40s are suffering from failing chassis. Even with these figures, Nissan will never accept liability.

magicbeard said:
Nissan GB claim they have not received any complains from D40 owners in the UK concerning Chassis Corrosion or Chassis Cracks.

That is just a fudge, they will have received many complaints just not recorded them, as they do not wish to accept liability.

magicbeard said:
Bit puzzled really ?

It is what it is, Billcar have shown interest, no doubt they have their reasons. Nissan will continue to keep their heads planted firmly in the sand until accident statistics with a direct link to corroding chassis' force them into a recall which is highly unlikely.

neilh · Aug 14, 2015

magicbeard said:
...the chassis is not considered to be an integral part of the vehicle...

:eekout

magicbeard · Aug 14, 2015

I had another call from Nissan GB about the cracking chassis issue today.

Its definitely a case of denial until such time that a fatality occurs and Nissan are forced to take responsibility.

May I suggest that D40 owners who have the same issue post some pictures and comments on the Nissan UK Facebook page ?

Sometimes "name & shame" tactics via social media make large organisations sit up and take notice. If nothing else I will alert other Nissan Navara D40 owners to the potential dangers so they can check their vehicles for chassis cracks before there is a serious incident or fatality.

lookskyward1 · Aug 14, 2015

magicbeard said:
I had another call from Nissan GB about the cracking chassis issue today.

Its definitely a case of denial until such time that a fatality occurs and Nissan are forced to take responsibility.

May I suggest that D40 owners who have the same issue post some pictures and comments on the Nissan UK Facebook page ?

Sometimes "name & shame" tactics via social media make large organisations sit up and take notice. If nothing else I will alert other Nissan Navara D40 owners to the potential dangers so they can check their vehicles for chassis cracks before there is a serious incident or fatality.

The Facebook thing is not a bad idea. Again the problem is getting in touch with all the victims :dunno

You have said you cannot weld your chassis, what do you intend to do with your truck now?

D40 Chassis rust

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