Nissan Navara Common Problems

The Navara is Nissan's one-tonne ute and one of the most common used 4x4 utes in Australia. Most for sale are the D40 (2005 to 2015) or the D23, launched as the NP300 in 2015. The D40 used the 2.5 litre YD25DDTi four-cylinder diesel, an early 4.0 litre VQ40 petrol V6 and, in the ST-X 550 from 2010, the 3.0 litre V9X V6 diesel with a 7-speed auto. The D23 runs the 2.3 litre YS23DDT single-turbo or YS23DDTT twin-turbo diesel with a 6-speed manual or 7-speed automatic, and most dual cabs have coil rear springs. Older D22 utes with ZD30 and YD25 diesels still turn up. The D23 is a clear step up in reliability; the D40's 2.5 litre diesel earned a poor name for timing chain and cooling faults.

Timing chain stretch (2.5L YD25DDTi, 2005 to 2015)

The YD25's timing chain can stretch well before the engine is worn out. Symptoms are a rattle from the front of the engine on a cold start, rough running and warning lights. If it goes far enough the chain can jump a tooth and the valves hit the pistons, which wrecks the engine. Some repairers advise replacing the chain set early as a precaution and checking it regularly after that, and aftermarket upgraded chain kits are sold. Expect roughly $1,500 to $3,000 for a chain job at an independent diesel workshop, far less than a rebuilt engine.

EGR cooler leaks and limp mode (2.5L YD25DDTi, 2005 to 2015)

The EGR cooler can corrode or split internally. Coolant then disappears into the exhaust without leaving a puddle, so the first sign may be a falling coolant level, white smoke or overheating that can damage the head gasket. Separately, 2012 to 2013 utes were prone to exhaust gas temperature sensor failures, which puts the engine into limp mode at about 2,000 rpm; Nissan ran a service campaign with a revised sensor. A replacement EGR cooler fitted costs roughly $800 to $1,500.

Auto gearbox damage from the radiator cooler (D40 5-speed auto, 2005 to 2015)

The automatic's fluid cooler sits inside the radiator tank. If the divider cracks, coolant mixes with the transmission fluid, which turns pink and milky and can destroy the gearbox. Some owners fit a new radiator as a precaution or add a separate external cooler. Some autos also shudder at 80 to 110 km/h under light load in top gear, a torque converter clutch fault fixed with a new converter. A radiator is a few hundred dollars; a rebuilt auto usually runs to several thousand.

Clutch slip and firewall cracks (D40 2.5L manual, mainly early builds from 2005)

Early D40 manuals were known for clutches that slipped and gave off a burning smell well before normal wear. Nissan later fitted an uprated clutch, flywheel and pedal box. Some utes also crack the firewall around the clutch master cylinder, which can stop the clutch disengaging properly. A clutch and flywheel replacement is roughly $1,500 to $2,500 depending on the parts used.

Chassis rails bending or cracking at the towbar (D40, 2005 to 2010)

On D40 utes fitted with a genuine towbar, the chassis rails around the towbar mounts could bend or crack under heavy loads. Nissan recalled the affected utes. Heavy towing and overloading are still a common cause of frame damage on used Navaras of any generation, and a few D23s have also been reported with bent chassis after overloading and fast driving on corrugations.

Rear coil spring sag (D23 coil-sprung models, mainly 2015 to 2016)

The five-link coil rear end on early D23 dual cabs was criticised for sagging under load, and some owners reported early sag even without towing. The steering also went light and vague when loaded. Nissan revised the rear suspension in later series, though the exact change dates vary between sources. The usual fix is heavier aftermarket springs or airbag helpers, roughly $800 to $2,000 fitted.

Oil leaks and hose wear (2.3L YS23DDT and YS23DDTT, 2015 to 2025)

Owners and buying guides report oil leaks on the 2.3 litre diesels, mostly from the rear main seal, the gearbox output seals, timing case seals and the turbo oil pipe. Oil dripping onto hot parts can cause smoke from under the bonnet. On twin-turbo engines the lower radiator hose can rub on the fan belt pulley until it leaks coolant, and the bottom intercooler hose can come off, causing a sudden loss of power. Rear axle seals also fail occasionally. Most leaks are roughly a few hundred dollars to fix; a rear main seal means pulling the gearbox and costs more.

Recalls and safety

D40 Navaras were covered by Takata airbag inflator recalls, along with recalls for rear wheel bearings, the lower steering shaft, engine stalling on early utes, cracked ST-X alloy wheel spokes and the chassis rails at the towbar. D23 recalls include an ignition switch on some 2017 utes that could switch the engine off and disable the airbags, steering knuckle bolts on mid 2020 builds, child seat tethers and winch remotes on 2021 to 2023 utes. Ask a Nissan dealer to check the VIN for open recalls, and see our recalls page.

Buying a used Nissan Navara? What to check

• Timing chain history: On a 2.5 litre D40, ask for proof the chain set has been replaced and listen for a rattle in the first seconds of a cold start.
• Coolant level: Check the coolant reservoir is full and ask whether it needs topping up, which points to a leaking EGR cooler or head gasket.
• Auto fluid: On a D40 auto, ask whether the radiator has been replaced or an external cooler fitted, and look for pink, milky fluid.
• Highway shudder: Drive at 80 to 110 km/h on light throttle and feel for a vibration that comes and goes.
• Chassis: Put the ute on a hoist and check the rails behind the cab and at the towbar for bends, cracks, rust or welding.
• Rear ride height: On a D23, see whether the rear sits low or has aftermarket springs or airbags, and ask what it has towed.
• Oil and hose leaks: Look under the engine and gearbox for oil, and on twin-turbos check the lower radiator hose near the pulley for rub marks.
• Clutch: In a high gear at low revs, accelerate hard and watch for the revs rising without the ute speeding up.
• Service records: Look for regular oil changes, ideally more often than every 20,000 km on a ute that tows or works hard.

Run a PPSR check to confirm the ute is not under finance or written off, and work through our Nissan Navara buying checklist before you pay.

The verdict

The D23 is the safer buy, and a 2017 or later ute avoids the softest early rear springs. Look for one with full service history and dry seals underneath. A D40 2.5 litre can still be a good, cheap ute, but only with proof of a timing chain replacement, a sound radiator on autos and a clean chassis. The ST-X 550 V6 diesel is often rated better than the 2.5, but check its service history just as closely. Avoid any D40 with an unexplained cold-start rattle, coolant loss or towbar damage.