2004 Ford Fusion 1.6L Petrol · SA54 AFV

A consistent pattern of lighting-related defects and recurring brake and exhaust advisories defines the roadworthiness picture of this 2004 Ford Fusion across its recorded test history. The registration plate lamp has been flagged as inoperative at every test since 2021, suggesting either a persistent bulb or wiring fault that has never been properly rectified, and the headlamp lenses have deteriorated progressively, reaching major failure status in September 2024 when both front headlamps were found to have product on the lens severely reducing light output. The most recent test on 3 September 2024 resulted in a pass, but only after the vehicle had failed the previous day on three major defects relating to the horn and headlamp output, indicating that remedial work was undertaken at short notice rather than reflecting genuine underlying improvement. The braking system has accumulated advisories over successive tests, with brake disc wear noted at the front in 2021 and worsening to pitted or scored condition by 2023, and a corroded offside front brake pipe flagged at the 2024 test. Exhaust integrity has also deteriorated, progressing from a minor leak advisory in 2022 to a major leak failure in 2023, and oil leaks from the engine have been recorded at four consecutive tests, though described as not excessive on each occasion. Against an age of roughly 22 years, the recorded mileage of 148,729 miles equates to an annual accumulation of approximately 6,760 miles, which sits broadly within typical parameters for a vehicle of this vintage and suggests regular rather than sporadic use. The testing history shows annual MOT entries without extended lay-up gaps, with tests recorded in 2021, 2022, 2023, and 2024, implying the vehicle has been kept on the road consistently and driven sufficiently to maintain system function. However, at this combined age and mileage, wear-related deterioration across braking, suspension, exhaust, and engine sealing components is to be expected, and the MOT history bears this out with advisories accumulating rather than clearing. The mileage alone does not raise particular concern, but the density of mechanical advisories at each annual test does point to a vehicle where consumable items are reaching the end of their functional life and will likely require attention in the near term. Prospective buyers should prioritise a close inspection of the braking system, given the documented progression of front brake disc wear and the corroded offside front brake pipe advisory from September 2024. On a test drive, listen for any grinding or pulsing through the brake pedal, which would indicate the pitted front discs have deteriorated beyond the advisory threshold, and check for a spongy pedal feel or any fluid seepage along the offside front brake line and its joints, as corroded brake pipes are a known failure point on older vehicles and can compromise braking integrity if left untreated. The recurring engine oil leak, while not currently excessive, warrants a physical check for fresh oil residue on the engine block and undertray, and the underside should be examined for oil contamination on adjacent components. The exhaust system warrants particular scrutiny given its escalation from minor to major leak status within a year. On a cold start, listen for any ticking or hissing from the rear section that would indicate an active exhaust leak, and check the mounting rubbers and heat shield security, as an insecure heat shield was also noted at the 2023 test. The headlamp output issue, which caused the September 2024 failure, should be verified by inspecting the lenses in person for hazing or product contamination, and all exterior lighting, including the persistently faulty registration plate lamp, the stop lamps, and the rear fog lamp, should be confirmed as fully operational. Given that the 2024 pass was achieved only by addressing defects flagged at the immediately preceding failure, any prospective purchase should include a thorough re-inspection of all items previously failed to confirm the repairs are durable rather than temporary.