Isuzu D-Max 2023 Problems

There’s a bit to unpack here. The first is that the D-Max is rated to safely tow 3.5 tonnes, so it’s not as if you constantly have the vehicle overloaded in terms of what it’s towing.

But if you also have the tray full of gear as well as 2.3 tonnes of caravan on the hitch, you might find that you’ve been inadvertently running overloaded for most of the time. It happens more than you think. At which point, the Pedders specialist is right; you need a suspension upgrade.

Even then, however, you still need to stay within the manufacturer’s maximum GCM (Gross Combination Mass) and the GVM (Gross Vehicle Mass) to stay legal. You can sometimes officially upgrade the GVM with a suspension upgrade that’s been properly engineered, tested and approved (which Pedders is a specialist in) but the GCM is generally not able to be upgraded according to the law in each state and territory.

But none of this explains why a vehicle designed to two 3.5 tonnes is wearing out its rear springs with 2.3 tonnes hitched up. Is the tow-ball down-weight within the legal limit (usually 10 per cent of the weight of the towed load)? Incorrect loading in this manner could affect the springs. Perhaps a fully-loaded visit to an accredited weighbridge might net more answers.

However, if it’s a simple case of the springs wearing out prematurely, then it’s possibly Isuzu’s problem to fix under warranty. Perhaps there was a bad batch of springs fitted at the factory that is affecting your vehicle and others built at the same time. Stranger things have happened.

A bit of sweating around the various parts of an engine where one component joins another is definitely not uncommon and not really a problem provided it's not actually dropping oil on the ground (at which point it's a leak, not a sweat-mark). But really, an almost-new vehicle like yours shouldn't be doing this at all.

The rear-main seal on the crankshaft is a likely culprit and a common source of leaks from this area, but since it's a big job (gearbox removal) to do it, I can understand why a mechanic would declare it okay and not to worry. The problem with that is that the sweating is likely to become a leak sometime down the track, at which point you'll have to act.

The good news is that because you've flagged this problem with Isuzu while the vehicle is still under warranty, it's called a pre-existing condition and is covered by the factory warranty, even if that warranty has since expired. However, one would hope that Isuzu does the right thing in the meantime and changes the offending gasket or seal to fix the problem.

Be very wary, however, about Isuzu (or more likely the dealer) claiming the problem is being caused by the catch-can you have had fitted. A good quality catch-can, with a relief valve and correct installation should not cause a rear main seal to leak. As for changing the grade of oil you're using, I doubt that it would do much, but since the alternative is a slightly thicker oil, it might just make the difference you're chasing.