2005 Ford Fusion 1.4L Diesel · AP55 AVT

A history of underside corrosion and emissions failures defines the earlier record of this vehicle, though the mechanical trend has improved, culminating in a clean pass on 19 February 2026. Previous tests highlight a recurring issue with the offside rear wheel bearing, which was flagged as noisy across 2023 and 2024, and a significant failure in 2021 due to excessive exhaust smoke. The record also shows a pattern of minor electrical faults and lighting adjustments, such as headlamp aim and position lamp failures, which were addressed prior to subsequent passes. With 124,112 miles recorded over 21 years, the vehicle has averaged approximately 5,910 miles per year. This low annual accumulation suggests the car has seen lighter than average use for its age. Mechanically, such usage patterns can sometimes lead to the accelerated degradation of rubber components or the onset of corrosion in areas where moisture traps, which aligns with the previous advisories regarding brake pipe corrosion and general underside rust. Inspection should focus heavily on the structural integrity of the underside and the condition of the brake system. Given the 2021 and 2022 advisories for corroded rear brake pipes and general underside corrosion, a physical check for surface rust or pitting on the chassis and fuel or brake lines is essential. During a test drive, listen for a rhythmic humming or droning sound emanating from the rear offside, which would indicate that the previously noted wheel bearing noise persists or has worsened. Attention should also be paid to the engine and exhaust system. The 2021 failure for excessive smoke levels indicates a previous issue with combustion or emissions control that requires verification. Check for any active oil misting or leaks around the engine block, as an oil leak was previously recorded. Additionally, assess the parking brake effectiveness and pedal feel, as the record previously noted high lever travel and a wearing brake pedal surface.