Nissan Navara D40 Exhaust System Buying Guide

Though now a little long in the tooth, the Nissan Navara D40 changed the way Aussies think of utes. When it was first released in 2005 as the bigger, bolder replacement of the D22, it appealed not only to traditional customers, tradies but also families. Better styling meant curved lines and more space – the main selling point for family cars. It came with powerful, but thirsty 4-litre petrols pumping out more power than most hot hatches of the day, or reliable and thrifty 2.5 litre 4-cylinder and 3 litre 6-cylinder diesels. Most used models today are diesels, and you can pick up a decent D40 with average mileage for around the third of a new facelifted D23.

The D40 was sold as either a dual-cab, or what Nissan called the ‘King Cab’, an extra cab with a huge tray. If you’re looking for an inexpensive but worthy off-road vehicle, the used-car market is the way to go. Most D40s have been handled with care and maintained regularly. And most will be fitted with bull or nudges bars, or a decent set of roof racks. The diesels don’t stick you to your seat when you press on the pedal, but a few modifications can solve that too. An aftermarket Nissan Navara D40 exhaust system will bring new life to your ute.

Types of Exhausts for the Nissan Navara D40

Diesels have a lot of pulling power or torque, great for hauling a fully-loaded tray or pulling a trailer. What they lack though is outright speed. Adding an aftermarket exhaust to the smaller diesel will see better performance, meaning you’re quicker to your job or the bush. Depending on how much you’re willing to spend, there are three types of exhausts for the D40, including the big petrol:

• Axle-back Exhaust Systems

Axle-back exhausts replace all the components in the stock exhaust from the rear axle to the exhaust tip. The parts include the muffler, the tailpipe extension, the tailpipe and the exhaust tip. The whole section is fitted to factory flanges or ‘slip fits’, using the original Navara mounting points, so no additional work is needed. Buyers can choose from smaller mufflers or resonators or large mufflers to completely deaden any sound coming into the cabin. You can also go the other way, with straight pipes, if you want more exhaust rumble. Axle-back Nissan Navara exhausts are one of the cheapest options, and the easiest and quickest to install.

• Cat-Back Exhausts

Cat-back exhausts replace all the stock parts from the catalytic converter to the exhaust tip. This includes the mid-pipe extension tube from the converter and all the parts in the axle-back systems. Like axle-back systems, cat-backs exhausts are simply bolted on the existing mounts in the Navara, so no drilling or welding is needed. Because of the extra piping, these are somewhat more expensive exhausts. However, for the money, you do get more performance gains, better emissions and a slight reduction in fuel consumption.

• DPF-back Exhausts

When all stock exhaust parts are replaced from the diesel particle filter to the exhaust tip, then a DPF-back exhaust is what you need. For both the diesel Navaras, this means also going with a better catalytic converter as an option. Tubing is either the standard 3 inches or the wider and straight 3.5 inches. If you want more performance and a better exhaust note go for the straighter, wider tubing. Quicker and hotter gases also means fewer emissions, good for the environmentally-conscious buyer.

• Header-back Exhaust Systems

Header back exhausts replace all the parts in the stock exhaust. Complete aftermarket exhausts can be used on all engines in the D40. For the diesels this will also include additional tubing to accommodate the turbo. This system provides the best gains in performance. Tubing is straighter, meaning better exhaust flow, and better combustion of diesel particulates and toxic gases. Diesel-specific converters feature on diesel exhausts for both 2.5 litre and 3-litre engines. Adding a dump pipe to the mix takes things up a notch. You’ll get shorter turbo lag times and save some fuel. As with the other exhausts, you can also choose the type of muffler and the exhaust sound you like best.

What to Look for In Nissan Exhausts

The first thing is to ensure if you’re buying aftermarket is that the exhaust fits the car. All the piping needs to fit the recesses in the undercarriage, with brackets and mounts provided to assemble everything in the existing mounting points. Wider pipes need not be an issue here. Most aftermarket systems are bolt-on types, so replacement is quick.

Since you’re spending for better performance (something you can check on a dyno), go for the best materials your budget can handle. Stainless steel grades differ here. 304-grade stainless steel is the toughest, with better corrosion handling and longer use life. If you’re regularly driving in the wet, then this is the best option. 409 stainless steel is the most used alloy in exhaust piping, though can develop rust over time if not cleaned. If money isn’t an issue, get steel and titanium alloy exhausts. Get your next Nissan Navara D40 exhaust from leading exhaust retailers in Australia.