2004 Ford Transit Connect 1.8L Diesel · FD54 ONK

The vehicle presents a concerning roadworthiness profile characterized by a trend of worsening structural and mechanical degradation. While it passed its most recent test in February 2026 at 159,723 miles, the record reveals persistent issues with corrosion. The tester recently flagged a corroded rear sub-frame and integral body structure corrosion, following a much more critical failure in November 2023 where the front sub-frame was described as seriously weakened. This progression suggests that the vehicle's structural integrity is actively declining, despite passing the minimum legal safety standards through reactive repairs. At 159,723 miles over 22 years, the Transit averages approximately 7,260 miles per year, which is consistent with a light commercial use of this age. However, the data shows a period of apparent neglect between November 2022 and February 2024, where the vehicle covered only 2,685 miles but suffered two consecutive failures. These failures involved significant mechanical faults such as a failing wheel bearing, ABS faults, and total indicator failure, indicating that maintenance is often only addressed when prompted by a failure rather than through a proactive preventative schedule. A buyer must conduct a thorough physical inspection of the lower chassis, specifically focusing on the sub-frames and outer sills. The history shows recurring issues with corroded brake pipes dating back to 2018, which are frequently covered in grease, a common tactic used to hide decay. Attention should also be paid to the suspension components, particularly the front anti-roll bar ball joints and wheel bearings which have been noted points of failure in the past. Furthermore, the recent advisory for front tyres worn close to the legal limit on uneven edges suggests basic consumable maintenance is currently overdue.