IsItAGoodCar
Reliability Guide

Common Problems with the
2004 Smart Forfour (454)

Launch of the first-generation Smart Forfour (W454) built on the Mitsubishi Colt platform, offering 1.1L, 1.3L, and 1.5L petrols alongside punchy 1.5L CDI diesels with manual or Softouch automated transmissions.

What changed for 2004

  • •Introduction of Smart's first five-door supermini sharing chassis and petrol engines with the NedCar-built Mitsubishi Colt
  • •Debut of 1.1L three-cylinder and 1.3L/1.5L four-cylinder petrols plus 1.5L CDI three-cylinder turbodiesels
  • •Sliding and folding rear bench seat fitted as standard across Pulse and Passion trim grades
  • •Choice of five-speed manual or optional six-speed Softouch automated manual gearbox

Common MOT watch-outs

  • !Worn front anti-roll bar drop links, track rod ends, and perished lower suspension ball joint dust covers
  • !Rear drum or disc brake imbalance and binding handbrake cables from infrequent urban use
  • !Headlamp aim misalignment and corroded rear registration plate lamp contacts
3
Known Issues
1
Serious
2
Moderate
0
Minor

All Known Issues

Clutch Actuator Failure

SeriousGearbox & Transmission

The automated manual gearbox uses an electric actuator that can fail, leaving the car unable to select gears.

Est. Repair Cost: £400–£800
Warning Signs:

Stalling when stopping, Refusal to engage gear, Warning light on dash

What to Inspect:
  • Ensure the actuator has been lubricated and adjusted according to service intervals
Verified by IsItAGoodCar Research Team

Rear Wheel Bearing Failure

ModerateSuspension & Chassis

Rear bearings are a known weak point and can start to drone or hum.

Est. Repair Cost: £150–£300
Warning Signs:

Droning noise from the rear that increases with speed

What to Inspect:
  • Jack up the rear and spin the wheels; listen for roughness
Verified by IsItAGoodCar Research Team

Front Suspension Wear

ModerateSuspension & Chassis

Wishbone bushes and anti-roll bar links wear out, leading to knocks and poor handling.

Est. Repair Cost: £150–£400
Warning Signs:

Knocking over bumps, Car pulling to one side

What to Inspect:
  • Listen for clonks during the test drive
Verified by IsItAGoodCar Research Team

Buying Tips for 2004 Smart Forfour (454)

  • Favour the conventional five-speed manual gearbox over the sluggish and prone-to-failure Softouch automated unit
  • Check the front and rear passenger footwells for moisture caused by blocked scuttle grommets or perished door rubbers
  • Test that the heater blower fan functions properly across all four speeds rather than only on the highest setting
2005
Check a 2004 Smart Forfour (454) by Registration