2004 Ford Focus 1.6L Petrol · YR04 FHG

Structural corrosion is the dominant mechanical story on this 2004 Ford Focus. The most recent test on 14 May 2026 recorded a Major failure for a front sub-frame corroded and seriously weakened, immediately flagging the vehicle as unroadworthy at the time of test. This sits atop a four-year pattern of progressive deterioration: rear sub-frame corrosion was first noted as advisory in October 2022, then again in October 2024, before escalating to a front sub-frame Major in 2026. Sill corrosion on both sides and corroded fuel pipework were also documented in 2024. Taken together, the underbody and chassis are showing age-related oxidation that has now reached the threshold of structural concern on a load-bearing component, and any prospective buyer should anticipate further corrosion work on remaining subframe sections, suspension pick-up points, brake lines, and sill repairs. The recorded mileage of 63,669 miles against a 22-year age equates to roughly 2,894 miles per year, which is unusually low. Six tests are recorded between 2022 and 2026, with mileage gaps of between roughly 1,500 and 4,000 miles between successive tests. There is no obvious multi-year lay-up, but the relatively modest annual accumulation means components such as brake discs, pads, callipers, tyres, and rubber suspension bushes have aged through time and oxidation as much as through wear. Low annual mileage does not insulate a 22-year-old vehicle from perishing rubber, seized brake mechanisms, corroded brake pipes, and dried or cracked flexible hoses, all of which are reflected in the test history. The MOT record shows a pattern of brake and underbody issues that should drive a targeted inspection. Brake pipe corrosion has been flagged on the offside front in 2022 and the nearside front in 2026, indicating the full length of rigid and flexible brake lines warrants close examination for surface rust, flaking, and any blistering of the protective coating. The front discs and pads were noted as worn, pitted, and thinning across the 2024 and 2025 advisories, and a fluctuating offside front service brake was recorded in 2022, so on a test drive expect to feel for pedal judder under firm application, any pulling to one side under braking, and a grinding or rubbing sensation from the callipers that suggests a seized slider. The track rod end ball joint play flagged as a Major in 2024 is a critical steering item; check for any knocking or clonking through the steering as the wheel is turned lock-to-lock, and for vagueness or wandering on the road. Rear wheel bearing roughness recorded in 2023 should also be reassessed, typically audible as a humming or drone that changes with cornering. Suspension and tyre conditions deserve equal attention given the recorded history. Both rear lower arms and both rear trailing arm front bushes were flagged for corrosion and wear in 2026, while rear suspension arm corrosion was noted in 2025 and rear lower spring seat damage in 2024. On a test drive, listen for clonking or rattling over speed humps and uneven surfaces, particularly from the rear, and feel for any vagueness or instability through high-speed corners. The 2023 and 2024 Dangerous failures for tyres worn to the cords on the offside front and nearside front respectively indicate a history of allowing tyres to run beyond legal tread depth, so all four tyres and the spare should be inspected for age-cracking, sidewall bulges, and uneven shoulder wear that may indicate alignment or suspension geometry issues. Finally, because the front sub-frame has been recorded as seriously weakened, a pre-purchase inspection on a ramp is strongly advised to assess whether remedial welding or sub-frame replacement has been carried out, and to confirm that the corrosion has not spread to adjacent mounting points, steering rack fixings, or sill-to-floor junctions.