Nissan Navara: D40 Rear Leaf Spring Cracking and Main Leaf Fracture

The D40 Navara rear suspension uses a multi-leaf spring pack that is known to crack and fracture, particularly the main (top) leaf. Cracking typically initiates at the spring eye or at the centre bolt hole, areas of maximum stress concentration. The failure is accelerated by regular heavy loading, towing, or corrugated unsealed road use. A fractured main leaf can allow the axle to shift laterally, creating a dangerous handling situation, particularly during braking or cornering. Cracked springs also cause the rear end to sit lower than normal. This fault is well documented in NZ and AU markets given the prevalence of tow and work use for D40 Navaras.

• Rear of vehicle sitting lower on one side or both sides
• Clunking or banging from rear suspension over bumps
• Visible crack or separation in leaf spring pack
• Vehicle pulling to one side under braking

1. 1

   Inspect each leaf spring visually with a torch for cracks, particularly at the spring eyes (both ends) and at the centre bolt location.

2. 2

   Check that the axle is sitting squarely under the vehicle — measure from axle housing to chassis rail on both sides.

3. 3

   Bounce each rear corner and listen for metallic clunking.

4. 4

   Check spring pack clamps and check if any leaves have separated from the pack.

Parts involved: Rear leaf spring.

$500 to $1,500 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

• “Has the vehicle been used regularly for heavy towing or carrying maximum payload?”
• “Have the rear leaf springs been inspected or replaced?”
• “Has the vehicle spent significant time on unsealed or corrugated roads?”

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.