2004 Ford Transit 2.4L Diesel · DW02 AAW

The vehicle remains roadworthy but the maintenance history reveals a persistent trend of deteriorating structural and fluid system integrity. While the most recent test in January 2026 at 140,217 miles resulted in a pass, it flagged widespread corrosion across all four brake pipes and noted general corrosion on the underside. The presence of grease or other material on these corro pipes suggests an attempt to mask surface rust rather than replace the components, a recurring issue that has appeared in every test since at least 2023. The mileage pattern is consistent with a 22-year-old commercial vehicle averaging approximately 6,400 miles per year. Between January 2023 and January 2026, the vehicle covered only 529 miles, indicating very low usage over a three-year period. This low mileage likely explains the advanced state of corrosion-related faults, as vehicles that remain stationary for long periods are more susceptible to moisture retention and oxidation, which has accelerated the degradation of metal brake lines and the structural integrity of the chassis. A buyer must conduct a thorough physical inspection of the underside to assess the extent of the rust. The January 2023 failure highlighted significant structural corrosion on the front spring mountings, and the subsequent advisories for underside corrosion suggest this process is ongoing. Particular attention should be paid to the rear prop shaft bearing, which showed play in the 2026 test, and the various suspension components, including worn bushes and wheel bearings that have appeared across multiple years. The recurring nature of the corroded brake pipes indicates a high risk of sudden fluid failure if the lines have not been replaced with new copper or steel alternatives.