Broken D22 "upward drive flange disc"

[yellalux]

Hey guys.

Just trying to find out some info from other D22 owners about whether they have heard of the 'upward drive flange disc' (basically the axle that comes out of the front diff) breaking?? My brother has a 2010 Navara and while out collecting firewood for camping we headed up a hill to go to a better spot and the component in question broke. The hill was by no means extreme, not a nice smooth driveway, was a bit rocky but easily driven. As he went through a bit of a hole the left front wheel lifted a little (lsd always kept forward movement though) and as he crawled through the hole a loud crack was heard. Had no idea what it was at first but later investigation we found the damage. Now the wierd thing is, the left wheel lifted so all weight was placed on RHS, but it was the LHS 'flange disc' that broke. The front diff centre is open and the spinning LHS wheel didnt come down with any force or anything as he was at low RPM. The crack noise was also heard while the LHS wheel was in the air.

Reason I'm trying to find some info is that Nissan won't replace the part under warranty, saying "we've never had that break before so you were obviously doing the wrong thing". I think it is a defective part, but Nissan don't seem to see it the same way.

If anyone has any info it would be appreciated. I guess the Nissan engineers worked really hard on this one part so it wouldn't fail, unlike the early 3 litre Patrol engines or the D40 bonnet latches and alloy wheels.....

[KiwiBacon]

Has the suspension been modified on this one?

[tweak'e]

ask at http://www.navara.asia/forum.php" onclick="window.open(this.href);return false;

i havn't heard of any CV or front axle problems. in fact the front diff is quite weak. so any serious abuse your going to break the diff gears first.
i would say its just a manufacturing fault.

[yellalux]

Has the suspension been modified on this one?

Suspension has been upgraded as the ute has tool boxes in the back normally. 2 inch kit was put in resulting in a bit over 1 inch lift in front.

ask at http://www.navara.asia/forum.php" onclick="window.open(this.href);return false;

i havn't heard of any CV or front axle problems. in fact the front diff is quite weak. so any serious abuse your going to break the diff gears first.
i would say its just a manufacturing fault.

Cheers for the link tweak'e I will check that out. I have heard the front diff in these things is fairly weak but I still thought CV's would be the weak point. I'm with you in thinking it's a manufacturing fault, just need to convince Nissan now.

[tweak'e]

2" lift won't cause any issues. there is issues when doing 3" or more.