2004 Peugeot Boxer 2.0L Diesel · AE04 FPC

The defining mechanical concern for this 2004 Peugeot Boxer is the pattern of recurring advisories accumulating over recent years, culminating in a Major failure at the same visit that ultimately produced a Pass. On 16 October 2025 the vehicle initially failed on a leaking fuel tank (6.1.3 (b) (i)), a serious defect that must have been rectified on the same day for the recorded Pass to also bear that date. That same inspection surfaced light oil misting from the offside front shock absorber, slight play in the offside front track rod end ball joint, a missing brake pipe clip on the nearside front, pitted inner brake disc faces, and a minor oil leak. Stepping back through the record, the 2024 test flagged corrosion to the front inner steps and arches along with an inoperative registration plate lamp, and the 2022 test noted minor corrosion in the offside front wheel arch area. The 2023 test was clean, but the broader picture shows progressive advisories touching structural corrosion, steering linkage wear, braking components, and fluid leaks across consecutive cycles. Against a 22-year service life, the recorded 83,654 miles equates to roughly 3,800 miles annually, which is low for a vehicle of this type and age. Such restrained usage typically points to either a light-duty commercial role or extended periods of standing. The MOT records themselves are continuous from 2022 onwards, with annual tests in October of each year, so there are no documented lay-up gaps to consider. Mechanically, low annual mileage on a large commercial platform can mean that moisture has had time to collect in the braking system, corrosion has progressed in structural areas without the benefit of regular heat cycles drying them out, and rubber components such as bushes and flexible brake hoses may have aged without commensurate wear. The 2025 advisories on the brake disc faces and brake pipe support are consistent with this pattern, as surface deterioration often accelerates when a vehicle sees short, infrequent journeys rather than sustained motorway use. For a prospective buyer, the front suspension and steering cluster flagged in 2025 warrants particular attention on a physical inspection. The slight play recorded in the offside front track rod end ball joint should be confirmed by rocking each front wheel laterally with the vehicle raised, listening for any clonking or feeling for unwanted movement, and then assessed on the road for any vagueness through the steering or uneven tyre wear across the front axle. The misting offside front shock absorber should be visually inspected for wetness running down the body and the test drive should include a check for reduced damping over successive bumps, such as the vehicle continuing to oscillate after a sharp press or rebound. Brake pedal feel should be firm and consistent, with no judder under hard application, given the pitted inner disc faces noted; uneven wear on the inner edges of the front tyres would corroborate the disc scoring. The front inner steps and arches, flagged for corrosion in 2024, should be examined with a torch and ideally probed, as commercial vehicle steps are notorious for trapping moisture and road salt, and any bubbling or flaking around seams, jacking points, or outriggers would warrant serious structural scrutiny. The fuel tank leak that triggered the 2025 Major failure is the single most significant item in the history and must be verified as fully resolved. A competent inspection should include a visual check beneath the tank and along the surrounding underbody, looking for fresh staining, wetness, or the smell of diesel, and the vehicle should be left standing during the viewing to confirm no fresh drips develop. The general oil leak recorded as not excessive should be monitored by checking the engine and gearbox undersides for accumulation on crossmembers, and a cold start from the viewing should be observed for any drips forming once the engine is warm. The nearside front brake pipe that was noted as having a missing clip but adequately supported should still be checked for chafing against the body or suspension components, as a clipped and properly routed pipe is preferable. Given the recurring corrosion advisories on this platform, a thorough appraisal of the floor, sills, rear chassis rails, and any cross members is advisable, and ideally an underbody inspection on a ramp would form part of any pre-purchase evaluation.