2007 Ford S-MAX 1.8L Diesel · YY07 EUU

Structural corrosion is the defining mechanical risk on this 2007 Ford S-Max, with the MOT record documenting a progressive deterioration of the integral body structure across multiple test cycles. The earliest recorded structural concern appeared at the June 2022 failure, where nearside outer sill and both rear inner sill sections within 30cm of body mountings were flagged with excessive corrosion seriously affecting strength. By the December 2023 test this had escalated into a major failure across the nearside rear outer and both inner rear structural sections, and most recently on 1 December 2025 the nearside and offside outer integral body structures were deemed to have corrosion reducing assembly rigidity to a significant degree. Following repair work the vehicle passed on 13 December 2025, but the documented history shows that structural corrosion on this platform is a recurring, advancing condition rather than an isolated incident, and any prospective buyer should anticipate further deterioration of sills, inner arches, and rear chassis leg sections within the near term. Mileage for this vehicle is not recorded in the data provided, which limits any year-on-year accumulation analysis, but the test cadence itself reveals something of the usage pattern. The vehicle was tested consecutively in late 2023 (19 and 23 December) and again in late December 2024 through early January 2025, consistent with a car in regular road use at year-end. The most recent pair of tests in December 2025 again shows a fail-to-pass sequence within roughly a fortnight, indicating the vehicle was driven to test, repaired, and returned. There is no evidence of a multi-year lay-up that would raise concerns about dormant brake corrosion, seized calipers, or perished fuel and coolant hoses, though the absence of mileage data means the rate of wear accumulation cannot be cross-referenced against component condition. The 2025 fail-to-pass sequence also highlights a serious safety defect beyond the structural items: both rear road wheel fixings were recorded as missing on 1 December 2025, alongside an excessively worn offside rear trailing arm bush. Wheel fixing loss is a critical integrity failure and any buyer must confirm that the correct number of studs, in serviceable condition, are present on both rear wheels and that the trailing arm bush has been replaced with a quality component rather than a temporary repair. The 2024 failure recorded both front tyres below the 1.6mm legal tread limit and a nearside rear tyre with structural separation, classed as dangerous, which underlines that tyre condition on this car has been a recurring compliance issue. The 2025 pass advisories show all four tyres now close to the legal limit again, suggesting that tyre replacement cycles on this vehicle are at the aggressive end of normal and should be budgeted for immediately after purchase. On a test drive, particular attention should be paid to the symptoms consistent with the recorded advisories and failures. With the brake discs and pads noted as wearing thin at both ends, listen for any metallic grinding or squeal under light braking and feel for pedal judder or vibration through the steering wheel, which would indicate the discs have worn beyond their limit and require replacement rather than just pad renewal. With the rear suspension arm corrosion and trailing arm bush wear flagged, accelerate gently over uneven surfaces and listen for clonking or knocking from the rear axle, particularly on transitions and over speed humps, and check for uneven rear tyre wear which would confirm arm geometry disturbance. Finally, given the recurring structural corrosion around the sills, rear chassis legs, and suspension mountings, place the vehicle on a ramp and physically inspect the inner sill seams, jacking points, and rear axle mounting areas for perforation, paying particular attention to any fresh welding, underseal, or filler that could be masking ongoing corrosion behind cosmetic repairs.