Parts most likely to break on 2nd Gen 4x4 Frontier?

[SD07NISMO]

For all you 2nd Gen 4x4 Frontier (and maybe 2nd Gen Xterra) owners: What parts have broken/failed on your vehicle while out on the trail? What was the cause of the failure? Did you do a trail repair, if so with what?

What I'm trying to put together is a small kit of emergency parts for trail repairs. I already have the small basics such as spare fuses, tire plugs, fluids, safety wire, duct tape, hose clamps, tools, etc. I'm mostly interested in the specific weak points of the Frontier and what I can reasonably plan ahead for.

Thanks in advance for any advice/info.

 

[fishy_frontier]

I've had zero failures on the trail to date. Any damaged parts have been due to me scraping rocks and such. I'll post a list of things so you can minimize the possibility of trail damage.

Mud flaps - I've dragged my mud flaps all over the place on rocky trails and finally removed them after they got chewed up on rocks. Optional solution: Buy or make flexible rubber mud flaps to replace the hard plastic ones.

Trailer wiring harness - If you plan on testing your maximum departure angle on a rocky trail you will probably drag your wiring harness and mount off the trailer hitch. I did and I used a zip tie to tie it to the hitch until I could repair it. Solution: Relocate the wiring harness somewhere on the bumper.

Skid plate bolts - For those running the factory skid plates I would highly recommend replacing ALL of the stock skid plate bolts with metric 8.8 or 10.9 grade bolts/washers from your local hardware store. I've sheered off at least 3 on rocks and another has broken off due to it rusting out (nothing else was rusted around it). It seems the metal in the stock bolts just isn't up to par.

That's about it.

 

[SD07NISMO]

Yeah the mud-flaps were definitely the first thing to go on my truck, not a very good design for the "off-road" package! I have already banged up the wiring harness pretty good so I should really consider moving it, although I don't do any towing and am not planning on doing any, so I might just be able to remove it? I like the suggestion for the skid-plate mounting bolts, I'll take a look at mine to see how badly beat up they are at this point.

 

[Coconut]

After 131,xxx miles:

Alternator @ ~70,000mi. (part failure)

Front & Rear Drive shaft U-joints @ ~100,000 mi (fatigue)

One OEM NGK spark plug @ ~56,000mi (fatigue/failure) - this triggered limp mode & P0304 code. no obvious reason for failure. Coil pack, cam phase sensor, crankshaft position sensor and fuel injector(s) tested positive for functionality. This could have been caused by poor gap even though they're pregapped from the factory. But, it should have been checked! That's my fault for not double checking before installing. All the remaining spark plugs were good. The failed spark plug seemed to be operating in the "HOT" range.

OEM SE Struts @ ~80,000mi (fatigue/abuse/failure)



These are the spare parts I personally would (and do) keep in/on the vehicle and possibly a new OEM ignition coil pack. Other than what's listed I've had a fairly stout 2006 SE 4x4 Frontier. Dont forget your basic stuff like replacement fuses, light bulbs, oil ect <-- I always forget those

 

[4Rescue]

Parts most likely to break on 2nd Gen 4x4 Frontier?

The driver... Seriously, aside from some issues with the Alu front Diff (is that even an issue with the 2nd Gen Fronty's??? I am drawing a complete blank right now) I haven't heard of manny issues with these trucks. At least not known major issues.

My best guess would be to take the same kind of "no-brainer spares" that you'd take with any truck (IE a CV, and the rest of the "get you home kit") because they're pretty damn reliable unless you're trying to crawl with the IFS and huge tries...

Cheers

Dave

 

[DigB]

This is certainly a good thread to have, I keep hearing about the IFS/Front Diff Grenading on the 2nd gen's. I am very curious as to why they break down is it part failure or Driver fault. From what I read the Frontier is very reliable and abuse for the most part is why stuff breaks on these trucks.

 

[fishy_frontier]

*Update to my previous post... I've had my first part failure at 103,800 miles. I was having problems with rough idle (below 1000rpm) and loss of power. I also received an SES (Service Engine Soon) light. After checking for codes the computer read P0021 = Intake Valve Timing Control Solenoid Bank 2 failure. It can be two things causing the issue, dirt or sludge inside the oil passages of the part or the actual electrical solenoid has given out. The solenoid is located at the top right side of the engine (Bank 2 is the drivers side). I tried to refurbish the part so I took it off, disassembled it, cleaned the oil passages with carb cleaner then flushed with fresh motor oil, then cleaned the electrical connection with electrical cleaner. It worked without a hitch for a 600 mile road trip but the solenoid has finally given out. Before it completely failed I could sit there while the engine was running rough and tap the solenoid with a wrench and the engine would run smooth for a short period of time. That is how I confirmed it was electrical. The reason for solenoid failure? Corrosion. There is heavy corrosion going under the electrical connection as seen in my picture below. I'm just waiting on my new part to get here (cost of part ~$140). Keep in mind I do live on the Texas coast and my truck does spend a lot of time on the beach which could have caused the corrosion due to the saltwater. I do think this is likely to happen to somebody else's truck given the fact that I keep my engine bay religiously clean. Also a P0021 code isn't really documented anywhere on the internet for a 2005-2011 Frontier, Pathfinder or Xterra.