. I operate this vehicle the same as every other I have ever owned .
I believe that is the problem.
I have owned a few navs now and travelled over 180'000km in my two D40's and i got over 370,000km out of my D22 none of them had a problem with the clutch.
BUT i had to drive the yd2.5 engine totally different to the ZD30 D22.
Due to when the power is produced from the tiny little 4cyl engine is why you need to pick up the revs A LITTLE before even thinking about letting your foot off the clutch, if you do that then just let your foot off the clutch as normal it will hook up just fine with NO slipping required.
I also own an old 2.8lt LN106 Hilux and that thing is like the good old utes always were and you could do anything you wanted to and got the thing off the line, let your foot all the way off the clutch with no go peddle at all then once the clutch is out stand on the gas or as the clutch is half way out start increasing the input from the go peddle, if you try and do that in the D40 it will either stall or leave the line with so little power the automatic thing to do is slip the clutch a little to help get it moving, BUT that results in not really going anywhere that much faster and putting load and heat through the DUAL MASS FLYWHEEL clutch set up and the "DMF" absolutely HATE even the smallest amount of heat, and its the heat that kills these things.
I noticed you said "I defy anyone to get a D40 moving without slipping the clutch" but it is 100% possible and i am willing to prove to anyone that will let me drive their ute that it can be done.
Dont get me wrong im not saying you cant drive, its more that the D40 has be driven different to any car that i have driven in the last 30yrs of driving, it does seem odd but give it a go.
Dont rev the shit out of it just pick up the revs BEFORE you even move your foot a mm then once the revs are up a tad let your foot off as normal, im sure you will be suprised by how well it hooks up, and if your at an intersection and need to get a quick turn in, try picking the revs up a tad higher again, then let the foot off the clutch as normal and it will shoot off like its in the power band.