IsItAGoodCar
Reliability Guide

Common Problems with the
2004–2006 Smart Forfour (454)

We've identified 3 known issues that can affect the 2004–2006 Smart Forfour (454). 1 of these are serious faults that could be expensive to repair.

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.

Most affected: Softouch / AMT models

Estimated cost: £400–£800Affects: 2004–2006Often appears around: 60,000–90,000 miles

Typical symptoms

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

What to inspect before you buy

  • ✓Ensure the actuator has been lubricated and adjusted according to service intervals

Rear Wheel Bearing Failure

ModerateSuspension & Chassis

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

Most affected: All models

Estimated cost: £150–£300Affects: 2004–2006Often appears around: 50,000–80,000 miles

Typical symptoms

  • •Droning noise from the rear that increases with speed

What to inspect before you buy

  • ✓Jack up the rear and spin the wheels; listen for roughness

Front Suspension Wear

ModerateSuspension & Chassis

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

Most affected: All models

Estimated cost: £150–£400Affects: 2004–2006Often appears around: 60,000+ miles

Typical symptoms

  • •Knocking over bumps
  • •Car pulling to one side

What to inspect before you buy

  • ✓Listen for clonks during the test drive

Buying Tips for the 2004 Smart Forfour (454)

  • ✓Check the plastic body panels for cracking or severe fading, particularly the roof panels which suffer under UV light.
  • ✓Listen for timing chain rattle on the Mitsubishi-sourced petrol engines, particularly on high-mileage cars.
  • ✓Verify the operation of the automated manual "Softouch" gearbox (if fitted); it can be jerky and the clutch actuator is a known weak point.
  • ✓Test the sliding rear seat mechanism to ensure it moves smoothly and locks securely into place.
  • ✓Inspect the front suspension for knocking; drop links and anti-roll bar bushes wear quickly.
  • ✓Check the central locking system, as the door lock actuators frequently fail.

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Other Smart Forfour (454) Year Periods

2004–2006

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