2004 Daewoo Kalos — MOT failures & pass rate
Across 2,742 MOT tests, the 2004 Daewoo Kalos recorded a 67.3% pass rate. That is 5.0 percentage points worse than all cars of a similar age, which fail at 27.7%. Failures cluster in suspension, lighting & signalling and brakes.
What the MOT record shows
No single area dominates — suspension (18.6%) and lighting & signalling (16.3%) are close, so failures are spread across several systems rather than one weak point.
At component level the recurring items are component mounting prescribed areas, headlamp aim and pins and bushes — component mounting prescribed areas alone was recorded 391 times.
Mileage is the strongest signal on the record: 22.6% of 0-30k cars fail, rising to 40.2% once past 120-150k.
Advisories point at the next bill rather than this one: suspension was flagged on 38.8% of tests without failing them.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Suspension | 18.6% | 511 |
| 2 | Lighting & signalling | 16.3% | 446 |
| 3 | Brakes | 11.7% | 322 |
| 4 | Visibility | 8.8% | 240 |
| 5 | Emissions & environmental | 8.1% | 222 |
| 6 | Body, structure & corrosion | 7.5% | 206 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Component mounting prescribed areas | 391 |
| 2 | Headlamp aim | 207 |
| 3 | Pins and bushes | 206 |
| 4 | Headlamp | 195 |
| 5 | Service brake performance | 179 |
| 6 | Malfunction indicator lamp | 167 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Suspension | 38.8% | 1,065 |
| 2 | Tyres | 29.4% | 806 |
| 3 | Brakes | 26.3% | 720 |
| 4 | Lighting & signalling | 24.0% | 657 |
| 5 | Emissions & environmental | 17.6% | 482 |
| 6 | Other defects | 17.5% | 481 |
Failure rate by mileage
Higher-mileage cars tend to fail more — often the most useful guide to real condition.
| Mileage band | Tests | Fail rate |
|---|---|---|
| 0-30k | 146 | 22.6% |
| 30-60k | 940 | 27.8% |
| 60-90k | 1,104 | 34.8% |
| 90-120k | 401 | 38.1% |
| 120-150k | 102 | 40.2% |
Failure rate by age
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 876 | 32.8% |
| 2022 | 681 | 33.5% |
| 2023 | 516 | 31.6% |
| 2024 | 379 | 32.7% |
| 2025 | 290 | 32.8% |
What to check before buying a 2004 Kalos
On a 2004 Kalos, suspension is what the MOT record says goes wrong most — it appeared in 18.6% of tests. Check these areas before you commit.
- Suspension (18.6% of tests): Worn drop links, bushes, springs or shocks — listen for knocks over bumps and check for uneven tyre wear. Typical repair: £150–£450 per corner.
- Lighting & signalling (16.3% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Brakes (11.7% of tests): Pads/discs are routine wear; binding, imbalance or corroded pipes are more serious — test for pulling under braking. Typical repair: £100–£350 per axle.
Repair costs are rough UK ballpark ranges to set expectations, not quotes — actual prices vary widely by car, parts and garage.
Frequently asked questions
How many 2004 Daewoo Kaloss pass their MOT?
67.3% of the 2,742 2004 Daewoo Kalos MOT tests in this dataset passed — a 32.7% fail rate.
What is the most common MOT failure on a 2004 Daewoo Kalos?
Suspension, recorded in 18.6% of tests, followed by lighting & signalling (16.3%).
Does the 2004 Kalos get worse with mileage?
Its MOT fail rate rises from 22.6% in the 0-30k band to 40.2% in the 120-150k band.
Methodology & source. Based on 2,742 MOT tests. Dataset: DVSA MOT testing data (2021,2022,2023,2024,2025). Data last updated 2026-07-27. Figures reflect MOT-testable defects only — read the methodology for how these are calculated and what they don't measure.