2004 Fiat Ducato 2.0L Petrol · WN54 HCK

Corrosion is the defining mechanical concern on this 2004 Fiat Ducato, appearing as an advisory in six of the seven recorded tests and culminating in the only failure of the record. The 2018 test recorded an excessively corroded nearside front subframe mounting outrigger as a fail item, and although the vehicle passed at the re-test three days later, that defect would have required structural repair to the underbody. Since then, every subsequent test has carried advisories relating to integral body corrosion, rear arches, sills, and inner wing suspension mount areas, indicating that the underlying rust problem has not been resolved but has remained within MOT pass tolerances. The most recent pass on 27 July 2026 continued this trend, adding front suspension arm bush wear on both sides and corrosion to both front coil springs, alongside perishing on both front tyres. The structural advisories consistently note that rigidity is not significantly reduced at present, but on a 22-year-old commercial vehicle with repeated corrosion advisories on load-bearing areas, this is the area most likely to escalate before the next test. Recorded mileage stands at 95,557 miles over 22 years, giving an annual average of roughly 4,344 miles. This is low for any motor vehicle, particularly a commercial van, and the MOT history reflects it through long gaps between tests, including a stretch of almost three years between the April 2019 test and the October 2022 test. Low annual mileage on a van of this age suggests either extended periods off the road or genuinely light operational duty, both of which carry their own mechanical considerations. Prolonged standing allows moisture to settle in brake discs, suspension joints, and exhaust systems, accelerating the surface corrosion already evident on the rear brake discs and underbody structure, while light use prevents consumables from being worn through normal operation. The pattern is consistent with a van used sporadically rather than as a daily workhorse. For a prospective buyer, the suspension and steering concerns flagged across multiple tests warrant close physical inspection. The 2026 advisories for worn front suspension arm pins or bushes on both sides, combined with the recurring play in the steering rack inner joint noted in 2018 and again in 2023, suggest that the front end is due for renewal of bushes and a steering rack assessment. On a test drive, listen for clonking or knocking from the front suspension over speed humps and uneven road surfaces, and feel for any vagueness, looseness, or knocking through the steering wheel when turning or traversing broken tarmac. The subframe outrigger that previously failed should be inspected carefully for any patch repairs, underseal masking fresh rust, or fresh welding, and the inner wing and suspension mounting areas should be probed for thickness. Coil spring corrosion noted on both sides is also worth checking visually, as corroded springs can fracture and cause a sudden drop in ride height. The brake and tyre items should not be overlooked either. The rear brake discs were flagged as pitted or scored in 2025 and the front discs as worn in 2022, suggesting the discs have been on the vehicle for some time and may be approaching the point where they require replacement rather than further machining. On test, any judder through the brake pedal, particularly under heavier braking, or a pulsing sensation through the steering wheel would confirm warped or excessively worn discs. The front tyres were noted as slightly perished in the latest test, and on a 22-year-old van rubber components harden with age regardless of tread depth, so sidewall cracking should be examined closely. Given the combined pattern of structural corrosion advisories, suspension wear, steering play, and brake disc deterioration, a pre-purchase inspection focused on the underbody, subframe mounts, and front suspension geometry would be prudent before committing to purchase.