D40 Nissan Navara

Please post the link for that article. I have not heard of this problem occurring in Oz.

There is probably rust in many vehicle chassis, but D40 and D22 are a bit iffy in that area before the axle.
I had quite a bit of experience with some during '14/'15 but the were mostly bent. Many were sold with factory bends in them.
There used to be a bent one I passed by in my town, I see the owner has disposed of it. Just a tray with overhang but obviously the load on the tray bent it. A tennis ball would roll off the rear of the tray.
Any rust would exacerbate that and cause a troublesome gap at the top.

dont forget the cast iron con rods camshafts!

The Spanish built d40 is the most troublesome. Places like superior engineering do chassis strengthening kits for them.

Found a reference - SPLIT HITS THE FAN Furious customers urge Nissan to recall 4X4 Navaras after it emerges that major fault could see trucks snap in HALF

Link.

Its a geographic issue, coupled with where and how they are stored prior delivery.

Jap / Thai built D22 Navaras don't have the problem.

It's no different to the current model Kluger which spent months outside in the north of America, with the holding area being sprayed and cleaned with salt due to the snow and ice. The first batch of current generation Klugers, arrived in Aus, with rust all over the under carriage. We were changing all the lower steering and suspension parts, prior to sale. Just what could be easily seen, when everything was new, black and shiny. Wouldn't want to own one in 10 years time. Maybe I'm just cynical, ( been in the industry too long ) but I'm sure we were sent the dodgy ones cause we cant send them back.
I suspect the same thing happened with the D40's in Europe, however I don't know of any cases reported here. The English equivelant of NRMA was doing inspections and demanding replacement vehicles, I think up to 10 yrs old over there. They don't have the same toothless tigers we have here though.
ACCC, NRMA, RACQ and the like don't realy have the nuts to take on the manufacturers. Too bad for the consumer.

Demanding Nissan pay for independent inspection. Reading this article and all your comments I am going to contact Nissan as I have a D40 purchased new. If they are riddled with these faults that you say they are I want to know the condition of mine. I Have printed this page and I am willing to go to the Dept. of Fair trading or their legal arm the NCAT commission armed with your statements here.