Jason-D40, after reading your initial post, I thought "bloody hell, that's awful" so I did something I don't usually have time to do and that is, I went a googled "hilux fuel injector" as I had heard that that is a problem with Hilux's.
Actually it's not a problem with the Hilux, it's a problem with the motor, so it's a problem for Hilux and Prado owners and there's a gazillion of them.
Anyway, they were all carrying on about their ****** motors, just like folks here carry on about the ****** clutches, diffs etc. All I'm trying to point out is that all makes and models have their own faults. You may ditch the D40 in favour of a BT50 for example, but you may also find the BT50 has its own batch of problems, I know the new Rangers have some sort of electrical problem.
My current thoughts are, knowing about the clutch, diff, timing chain and other problems are, if it breaks I'll fix it with better parts. Diff goes, I'll get a 2nd hand one and fit an air locker. Clutch, I'll get a single mass flywheel. Timing chain, I may go to a dual chain setup.
I don't think you can get vehicles like my old 1984 Hilux anymore that just don't break.
Everything new breaks, because they don't use metal as much anymore. You don't replace globes, you replace the assembly. You don't replace the diff, you replace the whole diff/axle assembly. It's quicker and cheaper to repair and assemble it all that way.
I've been into 4WD's since the early 80's and each decade they get softer (so to do the drivers, who, some of which, also get crazier).
I really believe, if you want a 4x4 that is going to stand up to punishment, you have to add lots of aftermarket gear to it, because they are just not being built as strong anymore.
Think about this. If you get a 2nd hand front diff, fit it with a locker, you shouldn't encounter that problem again. You've got the factory single mass flywheel, so you wont have that problem. The timing chain problem may never arise. If it does tackle that issue then. But if you jump from vehicle to vehicle you'll never debug any of your vehicles.
And another thing. It's definately time to find a reputable diesel mechanic and ditch Nissan service.
Good luck mate, I feel for you.
PS. - I think WoodyD40 picked up a 2nd had diff from Nis4x4Autospares (
http://www.niss4x4.com.au/home.aspx) for either $700 or $1400 bucks. My plan would be get one, fit an air locker and then bang the diff back in yourself.
PPS. Niss4x4 are Muster sponsors and nice blokes, so it's a good place to spend money.
After re-reading that, people will say things like "well they shouldn't build stuff that isn't fit for purpose" who has defined the purpose it is meant to be fit for?? Another thing, "well stuff like that shouldn't break" maybe it shouldn't, but it does, so you have to live with it.
I'm no lawyer, but I think I can say confidentently that if you go to court over this, you will find it would have been cheaper to just pay to get the diff fixed yourself.
Again, good luck.