2004 Ford Transit Connect 1.8L Diesel · MD04 FPP

A persistent pattern of brake pipe corrosion and front suspension deterioration defines the mechanical outlook for this 2004 Ford Transit Connect, with the most recent test on 30 January 2026 recording a pass but flagging a track rod end replacement just one day earlier following a failure. Across the four recorded test sessions, brake line corrosion has been flagged repeatedly, culminating in dangerous and major defects for the central, offside rear, and offside front brake pipes in late 2023 and early 2024, and the nearside front and rear pipes were noted as corroded at the 2024 test. Front suspension is also a recurring theme, with the nearside and offside front anti-roll bar linkage ball joint dust covers severely deteriorated across both 2025 and 2026, while the offside front track rod end recorded excessive play at the 2026 failure. The CV joint boots on the nearside front inner drive shaft have been logged as severely deteriorated on three separate occasions (2022, 2025, and 2026), suggesting they have not been replaced. The 2022 test additionally noted corroded outer sills and a corroded offside rear suspension mounting area, though these were not considered to significantly affect structural rigidity at that stage. With 143,606 miles accumulated over approximately 22 years, the vehicle has covered around 6,500 miles annually, which is broadly typical for a working van of this vintage. There are no extended gaps in the testing record, with annual tests consistently recorded from 2022 onwards, indicating the vehicle has remained in regular use rather than laid up for prolonged periods. This consistent usage pattern is consistent with light commercial operation, where braking and suspension components endure higher load cycles than a typical passenger car, and it is reflected in the corrosion findings on the underbody brake lines. A prospective buyer should pay particular attention to the condition of all underbody brake lines, as the central, offside rear, and offside front pipes have all been flagged for excessive corrosion requiring replacement within the last three years. A close visual inspection of the remaining pipework is warranted, looking for rust scaling, pitting, or any flaking that could indicate further deterioration. The front suspension warrants equally careful scrutiny: with the track rod end just replaced and both anti-roll bar linkage ball joint dust covers deteriorated, the linkages and bushes should be checked for splitting, play, or knocking when the wheel is rocked by hand, and any clonks or rattles over uneven surfaces during a test drive should be taken seriously given the recurring advisories. The offside front wheel bearing, which was recorded as rough when rotated at the 2024 failure, should also be assessed for any hum or drone that changes with vehicle speed, indicating renewed wear. The front inner CV joint boots have been flagged on three separate tests and should be inspected for tears or grease loss, as a failed boot will eventually lead to joint wear and a potential clicking noise on turns. The exhaust system should be checked for leaks and secure heatshields, as a major exhaust gas leak was recorded at the 2025 test. Outer sill corrosion was noted in 2022, so a thorough examination of the sill seams, jacking points, and suspension mounting areas for any progression of rust is advisable. Finally, ensure that all lighting, wipers, and the windscreen washer system are functioning correctly, as these have been flagged for failure across multiple tests, and confirm the tyres have adequate tread depth and no sidewall damage, given the dangerous tread depth failures recorded in 2025 and the worn edges noted at the most recent test.