2003 Ford Transit 2.0L Diesel · PF03 AOP

The November 2021 test at 154,567 miles resulted in a pass only after an initial failure on the same day for corroded brake pipes coated in grease and chassis corrosion at the inner and outer sills within 30 centimetres of mountings. The maintenance trend shows a clear, long-term deterioration in structural integrity rather than stability. Since 2017, testers have repeatedly flagged excessive corrosion seriously affecting strength at rear spring mountings, seat belt anchorages, and chassis leg mountings; the 2021 advisory confirms this rot persists at critical load-bearing points despite previous undersealing attempts. Mileage accumulation has slowed to roughly 3,700 miles per year over the last decade, rising from 113,001 miles in 2010 to 154,567 miles in 2021. A notable gap exists between the 2015 test at 139,047 miles and the 2017 test at 146,123 miles, suggesting a period of limited use. No test record exists since November 2021, leaving nearly five years of unknown condition and mileage unaccounted for. Brake pipe corrosion has featured on every test since 2017, escalating from slight corrosion on the main feeds to excessive rear pipe corrosion in 2018 and 2019, before appearing as grease-covered pipes along the full length in 2019 and 2021. The 2018 failure recorded seized load-sensing valves, pitted front discs seriously weakened, and front brakes recording little or no effort; while the 2021 pass shows no performance failure, the underlying pipe degradation remains unresolved. Front tyre damage — cuts to the cords in 2019 and a structural lump in 2018 — indicates periods of neglected tyre maintenance. Suspension components show chronic wear: rear spring mountings failed on corrosion in 2017, front wishbone rear bushes showed excessive movement in 2017 and wear in 2018, and anti-roll bar links and driveshaft joints exhibited play by 2018. A buyer must physically verify the structural soundness of the chassis legs, inner sills, and spring mounting towers, ideally with a hammer test and lift inspection. The brake pipe network requires full replacement verification, not just grease coating, and the load-sensing valve function must be confirmed. Front suspension bushes, ball joints, and wheel bearings need close assessment for the play recorded across multiple tests.