2004 Toyota Hilux 2.5L Diesel · FD54 LEF

The most recent DVSA examination on 16 September 2025 returned a PASS, although the test was preceded only thirteen days earlier by a FAIL on 3 September 2025 carrying an identical set of advisories relating to inner sill repairs, general structural corrosion, and a corroded nearside rear body mount. Because the failure did not progress to test and the same items were carried over as advisories on the subsequent pass, the overall maintenance trend cannot be interpreted as either improving or stable; it indicates that the underlying structural and corrosion concerns were present throughout 2025 and have not been rectified. Across the recorded MOT history, advisories for front suspension components, wheel bearings, and brake wear have recurred consistently from 2021 through 2024, while structural corrosion advisories have appeared annually since 2022, demonstrating a slowly worsening condition typical of a vehicle now exceeding twenty-two years of service. At 159,629 recorded miles over roughly twenty-two years, this Hilux averages around 7,256 miles per year, which is a credible and broadly typical annual figure for a working light commercial vehicle. The MOT records span 2021 to 2025, with no apparent extended gaps in testing, and the mileage progression suggests the vehicle has been in regular rather than intermittent use. While the headline annual mileage is modest, the consistency of corrosion advisories on structural members, sills, and body mounts points to cumulative exposure rather than neglect, and the persistent front suspension wear items are consistent with a working vehicle that has completed many low-speed, laden, or rough-road miles which place particular stress on bushes, ball joints, and wheel bearings. Given the recurring advisories, a prospective buyer should pay close attention to the front suspension and steering geometry. Both front lower suspension arm ball joints have been flagged with slight play on multiple tests, and on a road test you should listen for clonks or knocks over speed humps, uneven or feathered front tyre wear suggesting geometry misalignment, and vagueness in the steering. The nearside front wheel bearing has likewise been an annual advisory since at least 2022; this typically presents as a humming or droning noise that changes with cornering and may indicate the bearing is nearing replacement. The offside front upper suspension arm has corroded progressively, and combined with shock absorbers previously noted as having reduced damping effect, the vehicle should be checked for excessive body roll, pitching under braking, or a generally unsettled ride. Brake pedal feel should be assessed for the offside rear binding previously recorded, watching for pulling to one side or uneven rear brake disc corrosion, while the prop shaft bearing advisory from 2021 merits listening for vibration or a cyclical knocking from beneath the centre of the vehicle at speed. On the structural side, the repeated advisories for repaired inner sills, general structural corrosion, and a corroded body mount are the most significant long-term concerns. A buyer should physically inspect the inner sills, chassis rails, jacking points, cab mount areas, and the rear body mount for advanced perforation, flaking rust, or evidence of poor-quality repair, remembering that advisories only confirm structural rigidity is not significantly reduced at present and that corrosion will progress. Given the vehicle's age, supplementary checks should include the condition and date codes of all tyres for sidewall cracking or perishing regardless of tread depth, the 12V battery's age and state of charge, the brake fluid and coolant for calendar-based degradation, and the timing belt service interval if not documented, as the 2KD or 1KD engine fitted to this generation Hilux has a critical replacement schedule. A thorough underside inspection on a ramp, confirmation of full service history, and attention to any oil leaks from the engine or rear differential would be strongly advisable before purchase.