Nissan Dualis Gearbox & Transmission Problems

In conventional automatic transmissions, a delay when selecting gears (often reverse) indicates worn internals and the need for a rebuild. Your Nissan is fitted with a CVT transmission rather than a conventional auto, but it still operates on the basis of hydraulic control. Which means that the problem could still be one of internal wear. A transmission specialist is likely to be your best point of contact for this problem.

The first thing to do, though, is check the level of fluid in the transmission. A level that is low can mean delays when selecting gears and even slipping of the transmission under load. However, if the level is low, there must be a leak somewhere as these are sealed systems and should not require regular topping up.

A car that continually breaks the same component time after time probably has a bigger problem than simply the part that keeps breaking. It sounds like you need to have the transmission and torque converter checked for alignment and correct interface. Any problem with the way they fit together could explain why an O-ring keeps failing. Continuing to replace the O-ring won’t fix a more complex problem.

Either that, or the mechanic who is changing the O-rings is making the same mistake over and over again and not using the correct lubrication or fitting procedure.

Clutch life in most cars is determined by the type of driving you do and the type of driver you are. Cars that do a lot of urban running or towing will almost always have a shorter clutch life. Those used for highway journeys where the gears aren’t being changed as frequently tend to have longer clutch life.

But it’s also true that a driver who is gentle with the clutch and gearshift (as opposed to one who makes fast, hard changes) will also stretch the clutch’s lifespan.

I don’t think 100,000km out of a clutch is any reason to complain and suggests that you’re one of the gentle drivers out there. But before you commit to replacing the clutch, make sure that the slipping is not from poor clutch adjustment or oil on the clutch from a leaking engine seal, rather than a truly worn-out clutch. Of course, even if it is a worn oil seal (the rear-main seal is the most likely culprit) the gearbox and clutch must be removed to fix it, so a new clutch at 100,000km would be a good idea anyway to avoid having to remove all those components later for a clutch change.

The dual-mass flywheel was introduced to reduce the vibrations in the driveline, so in that sense the mechanic was right, but unless you’re very sensitive you’re unlikely to be bothered by any vibrations that might result from changing to a single-mass flywheel. The advantage of switching to a single-mass flywheel is that the clutch is likely to last longer and be cheaper to replace when it does wear out.

I’m not surprised at the clutch requiring replacement in that time, but I am surprised at the gearbox problem. I would contact Nissan directly and ask for some assistance with the cost of repairs.

While the CVT is a brilliant concept there have been problems with turning the concept into a reliable functioning gearbox, despite 40 years of trying. Shuddering can be a problem with them, and while Nissan might want to dismiss it as a characteristic of the transmission, it's only because they don't know how to fix it. You should do as it has been suggested, make a formal complaint, and pursue a settlement through official channels.

Nissan spokesman Peter Fadeyev replies: "Nissan Australia has encountered only a handful of episodes where the Dualis shifter has been broken but these have been observed in rental cars and cars with certain aftermarket accessories fitted. The cause of the breakage is excessive force applied to the shifter to engage the car into gear without the driver applying sufficient force to the brake pedal to allow the car to be disengaged from the Park position. This matter hasn't involved recall." 

Nissan told us that the clutch in your car showed normal, even wear, but the issue of clutch wear is a tricky one. Clutches are not covered by the warranty, which is fair enough given that they do wear out, but I think owners are entitled to expect the clutch to last a reasonable time and distance before requiring replacement. Having worn out in 38,000 km of normal driving without any towing is unacceptable in my view, and something Nissan, and every other carmaker, should be addressing. In this case it's Nissan that is affected, but it happens with other makes and models. Perhaps, given the overwhelming popularity of automatic transmissions, and the diminishing demand for manuals, they simply don't care. Think about having a heavy-duty clutch installed, that way you should get a decent run out of it before you next need to replace the clutch.

Clutches seem to be a particular problem with Nissans; you’re not the only one who has come to us for advice. The response you received from Nissan is the one most owners get when complaining about the life of the clutches in their cars. You could pressure Nissan in the hope they will relent and examine the clutch, but even if they did I’m sure you would find that the clutch is worn out. I doubt very much if you would get Nissan to come to the party and cover the cost of a replacement; the best course of action is to install a heavy-duty replacement clutch and a solid flywheel. I would urge you not to install a standard Nissan clutch and dual-mass flywheel, as you are likely to have the same issue all over again in another 40,000 km or so.

It would seem you have a number of valid concerns about the car. Write a letter to your dealer detailing the problems you have experienced with the car and your disappointment, and request a meeting with them and a Nissan representative so you can express your concerns face to face and thrash out a program of work to fix the car.