2002 Ford Fusion — MOT failures & pass rate
Across 4,330 MOT tests, the 2002 Ford Fusion recorded a 70.8% pass rate. Superminis of a similar age fail at 29.4%, so the 2002 Fusion sits squarely on the average. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
Lighting & signalling dominates the failure mix at 19.6% of all tests — 6.1 points clear of suspension, so it is the first thing to check.
At component level the recurring items are headlamp aim, headlamp and stop lamp — headlamp aim alone was recorded 451 times.
Condition tracks the odometer closely. Failures run at 20.2% in the 0-30k band and 30.6% in the 150k+ band, a 10.3-point spread.
Fuel type barely separates them — petrol fails 29.0% of the time against 29.7% for diesel.
Advisories point at the next bill rather than this one: brakes was flagged on 37.5% of tests without failing them.
The trend is improving — the fail rate fell from 31.6% in 2021 to 28.7% in 2025, as the worst-kept examples leave the fleet.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 19.6% | 847 |
| 2 | Suspension | 13.5% | 584 |
| 3 | Brakes | 12.2% | 530 |
| 4 | Visibility | 7.1% | 306 |
| 5 | Emissions & environmental | 6.7% | 291 |
| 6 | Tyres | 5.4% | 234 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Headlamp aim | 451 |
| 2 | Headlamp | 342 |
| 3 | Stop lamp | 331 |
| 4 | Catalyst emissions | 309 |
| 5 | Rigid brake pipes | 279 |
| 6 | Service brake imbalance | 266 |
Top advisory categories
Advisories aren't failures, but they flag work likely needed soon — useful when budgeting.
| # | Category | % of tests with advisory | Tests |
|---|---|---|---|
| 1 | Brakes | 37.5% | 1,625 |
| 2 | Suspension | 34.2% | 1,482 |
| 3 | Tyres | 30.1% | 1,305 |
| 4 | Lighting & signalling | 22.3% | 967 |
| 5 | Other defects | 18.5% | 802 |
| 6 | Emissions & environmental | 16.6% | 718 |
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 | 84 | 20.2% |
| 30-60k | 516 | 22.5% |
| 60-90k | 1,263 | 27.9% |
| 90-120k | 1,334 | 31.0% |
| 120-150k | 775 | 32.4% |
| 150k+ | 327 | 30.6% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 3,321 | 29.0% |
| Diesel | 1,009 | 29.7% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 1,261 | 31.6% |
| 2022 | 1,021 | 28.9% |
| 2023 | 837 | 27.0% |
| 2024 | 682 | 28.0% |
| 2025 | 529 | 28.7% |
What to check before buying a 2002 Fusion
On a 2002 Fusion, lighting & signalling is what the MOT record says goes wrong most — it appeared in 19.6% of tests. Check these areas before you commit.
- Lighting & signalling (19.6% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (13.5% 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.
- Brakes (12.2% 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 2002 Ford Fusions pass their MOT?
70.8% of the 4,330 2002 Ford Fusion MOT tests in this dataset passed — a 29.2% fail rate.
What is the most common MOT failure on a 2002 Ford Fusion?
Lighting & signalling, recorded in 19.6% of tests, followed by suspension (13.5%).
Does the 2002 Fusion get worse with mileage?
Its MOT fail rate rises from 20.2% in the 0-30k band to 30.6% in the 150k+ band.
Methodology & source. Based on 4,330 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.