2004 Ford Fusion 1.4L Diesel · BT04 AOZ

The vehicle presents a worsening maintenance trend regarding structural integrity and fluid containment. While it passed its most recent test on 4 October 2025 at 151,174 miles, the record shows persistent corrosion issues. Specifically, the tester flagged both nearside and offside rear vehicle structure or chassis corrosion within 30cm of a mounting. This corrosion issue is not new; it appeared in the 26 October 2024 test at 147,577 miles and represents a continuation of degradation noted in previous years. The mileage accumulation is consistent with a vehicle of this age, averaging approximately 6,872 miles per year over its 22-year lifespan. The data shows steady progression from 52,564 miles in April 2011 to the current 151,174 miles. There are no significant gaps in the testing history, suggesting the vehicle has been in regular use. The gradual increase in mileage aligns with a typical commuter pattern rather than long periods of inactivity. A prospective buyer must conduct a thorough physical inspection of the underside to assess the extent of the chassis corrosion. The recurring advisories for structural rust near the rear mountings suggest that while the vehicle remains legal, the metal is thinning. You should also investigate the engine bay for the oil leak first identified in the 6 October 2022 test at 140,317 miles. Although the tester noted it was not excessive at that time, the presence of engine covers and under trays preventing full inspection in 2021, 2022, and 2023 indicates that mechanical components have been difficult to access for maintenance. The brake system requires close scrutiny. The record shows a history of corroded brake pipes, specifically noted on both front pipes in October 2022 and both rear pipes in October 2020. Although the vehicle passed its recent tests, the repeated presence of corrosion on hydraulic lines and the previous advisory regarding a smooth brake pedal suggest that the braking hardware is ageing. Check the condition of all brake lines and the integrity of the fuel and hydraulic connections to ensure the corrosion has not progressed beyond the points previously flagged by testers.