2004 Toyota RAV4 2.0L Diesel · SB54 ADZ

The vehicle presents a concerning history of escalating structural degradation, particularly regarding the chassis and suspension. While the most recent test in October 2025 at 120,454 miles passed, the record notes a corroded rear sub-frame that was not yet seriously weakened. This follows a significant failure in August 2025 where the tester identified excessive corrosion on the nearside rear inner suspension mounting areas across the sill, valance, and lower wheel arch. The presence of these structural issues, combined with previous reports of surface corrosion on all suspension components, suggests that the vehicle is reaching a stage of terminal rust despite its low mileage. At 120,454 miles over 22 years, the car has averaged approximately 5,475 miles per year. This low-use profile has not prevented the typical deterioration of rubber components and metal age-related oxidation. Between July 2024 and August 2025, the vehicle covered only 3,319 miles, yet it suffered multiple failures related to fractured coil springs, leaking shock absorbers, and structural corrosion. The high frequency of tests in the last 18 months indicates an active attempt to keep the vehicle roadworthy, but the recurring nature of the mounting point failures suggests the underlying metal is thinning. Braking maintenance shows an inconsistent pattern of reactive repair. Records from 2024 show the tester flagging imbalanced brakes, thin pads, and significantly worn discs, followed by binding calipers in the subsequent test. The suspension has also required frequent attention, with worn arm bushes and defective anti-roll bar linkages noted repeatedly across several years. A buyer should be wary of the gearbox mounting issues and the engine management light failure from 2023, as these point to deeper mechanical neglect. The primary risk remains the structural corrosion on the suspension mounting points.