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D40 ongoing maintanence and parts
  #1  
Old 09-07-2017, 02:40 AM
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Default D40 ongoing maintanence and parts

Hi All

Just wondering what parts people have replaced on there d40's over the years.I've got a 2010 thai d40 and i love it. has done 162k km with out any problems. I have had the timing chain done and uni's on tail sharft but thats it.
Was wondering what other parts people have had to replace to get them to 500k km or so.

cheers
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Old 09-07-2017, 11:28 PM
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07 auto STX diesel spainbuilt 115,000 ks
Replaced so far:

Suction control valve

Turbo boost sensor and all vacuum lines, old lines turned to dust

Rear tailshaft unis

Front bearing hubs

All fuel lines, old ones were cracked and sh**ty

Water pump

Fan clutch viscous drive

Auto trans radiator cooler bypass, fitted new trans cooler unit
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Old 09-07-2017, 11:30 PM
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Oh yeah, and the timing chain snapped at 70,000 ks so new Iwis timing chain, dual row chain kit and a brand spankin new head
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Old 10-07-2017, 11:47 AM
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Well I've had a few things replaced on my 2009 STX Auto.

* Right front wheel bearing
* Turbocharger
* Rear uni
* Rear diff rebuilt
* Transfer case bearings and seals (front and back)
* CV boots * zillion
* SCV
* turbocharger actuator control solenoid
* All vac hoses
* new auto trans radiator cooler fitted externally
* Radiator recored

I have had my throttle body replaced, as well as my throttle position sensor, but I don't believe these were needed (the mechanic hadn't diagnosed the faulty SCV). I've had other things replaced (mirrors -> Clearviews, towing plug was shit, Pioneer head unit was shit) but they're not from manufacturing failures or "worn out too early" issues.

I didn't mention having to replace my front disc rotors at 40K? Yeah, they were crap.
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Old 10-07-2017, 09:44 PM
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Old Tony
have you replaced your timing chain I know its not listed but just wanted to make sure.
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Old 10-07-2017, 11:35 PM
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No, had it checked several times, but I'm still on my original timing chain. No extraordinary noises from the front of the motor and we just returned from another 3,000+km trip towing the van (went to Wilpena Pound and Port Augusta) with no dramas.
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Old 11-07-2017, 02:36 AM
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Since getting mine, 3 years ago i've done the following.. (2008 D40 STX)

Remove / clean replace DPF
REMOVE DPF and put in DPF Delete and Calibrated sensors (DPF Stuffed)
CPS Sensor
Remove, clean and replace ECM (12 month ongoing issue with random limp mode - this was eventually the magic bullet)
Timing chains x 2.. Yes, the first one from Engines Australia failed after 25,000 and I needed another one. Expensive that was!
SCV x 2 (2nd one turned out to be not required, it was the pump needing a rebuild)
Remove and rebuild diesel pump
Viscous Fan remove and replace
Boost control Solenoid. After 2nd one started to fail replaced it with a Tillix - Never looked back
All boost vacuum lines
Radiator
Front rotors.
All Earth wires removed and either replaced, or re-crimped and terminated.

If i added it all up, i'd cringe and cry. It's a great drive when it's running smooth - just the headache and constant search for a new issue can be tiring!
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Old 11-07-2017, 08:04 AM
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I spoke too soon. This morning went to go for a drive and the car started fine. Pulled out from the curb and thought "hmm, maybe it's just a little off because it's cold ..." then tried to climb a nearby (small) hill. No. Not happening. Boost gauge is showing vacuum (and I know it's calibrated correctly - it worked fine yesterday). While waiting in town, I looked at the turbo actuator - it wsa moving up and down at idle just like you'd expect. Okay, so boost control solenoid is ok, vac lines are ok, actuator is ok, vanes are moving.

When I returned home after the slow (but vital) drive, I popped the bonnet and pulled the hose from the turbocharger inlet and tried to turn the impeller. Nope. Not budging. My $770 Forefront turbocharger is dead after 70,000km. Yes, I tow, but I am quite aware of the correct procedure to shut the engine down even after a long haul and employ a (not quite legal) turbo timer to assist.

So I'm putting my original turbocharger back in - and I'm buying a replacement (new) turbocharger for $356 delivered. Yes, that's correct.

Actually, I'm not putting it back in. I'm basically one-handed these days, so I save me bickies and pay for a mechanic. And I'll pay him again when my new one arrives.

When I get this one pulled out I'm going to strip it down and examine what caused the failure. I'm pretty annoyed that it's blown, but I'm very thankful that it went this morning and not yesterday while I was still west of Cobar NSW!
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Old 11-07-2017, 08:16 AM
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Heard of a few failures with the Forefront Turbo's Tony, so your not on your Pat Malone.

New Turbo for $365 is very nice pricing indeed..

Perhaps your Boost Solenoid had the turbo at full boost and over-drove the unit?
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Old 11-07-2017, 01:42 PM
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Forefront turbos are chinese made, and no doubt a $365 turbo would be too

You cant expect the same quality and longevity from a chinese product as you would (usually) get from a japanese or US built turbo
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