2003 Ford Fusion — MOT failures & pass rate
31,064 MOT tests on the 2003 Ford Fusion are in this dataset, and 71.9% of them passed. Against superminis of a similar age (29.4% fail rate), the 2003 Fusion comes out 1.3pp better. Failures cluster in lighting & signalling, brakes and suspension.
What the MOT record shows
One area stands out: lighting & signalling, recorded in 20.1% of tests against 12.2% for the next-worst category.
At component level the recurring items are headlamp aim, rigid brake pipes and headlamp — headlamp aim alone was recorded 3,387 times.
A 150k+ example is materially riskier than a 0-30k one: 32.4% versus 18.9%.
Fuel type barely separates them — petrol fails 28.1% of the time against 28.2% for diesel.
Brakes is the most common advisory, noted on 39.9% of tests — work that passed today but is likely due soon.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 20.1% | 6,228 |
| 2 | Brakes | 12.2% | 3,799 |
| 3 | Suspension | 12.1% | 3,757 |
| 4 | Emissions & environmental | 6.9% | 2,131 |
| 5 | Visibility | 6.6% | 2,059 |
| 6 | Tyres | 4.9% | 1,521 |
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 | 3,387 |
| 2 | Rigid brake pipes | 3,204 |
| 3 | Headlamp | 2,663 |
| 4 | Stop lamp | 2,176 |
| 5 | Catalyst emissions | 2,001 |
| 6 | Wipers | 1,485 |
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 | 39.9% | 12,388 |
| 2 | Suspension | 30.6% | 9,507 |
| 3 | Tyres | 29.3% | 9,100 |
| 4 | Lighting & signalling | 20.7% | 6,426 |
| 5 | Emissions & environmental | 16.0% | 4,972 |
| 6 | Other defects | 15.3% | 4,761 |
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 | 475 | 18.9% |
| 30-60k | 3,593 | 20.1% |
| 60-90k | 9,304 | 26.2% |
| 90-120k | 9,826 | 29.8% |
| 120-150k | 5,304 | 32.4% |
| 150k+ | 2,357 | 32.4% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 25,123 | 28.1% |
| Diesel | 5,941 | 28.2% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 8,916 | 28.3% |
| 2022 | 7,349 | 28.1% |
| 2023 | 6,026 | 27.7% |
| 2024 | 4,900 | 28.3% |
| 2025 | 3,873 | 28.0% |
What to check before buying a 2003 Fusion
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 20.1% of tests. Start there.
- Lighting & signalling (20.1% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- 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.
- Suspension (12.1% 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.
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 2003 Ford Fusions pass their MOT?
71.9% of the 31,064 2003 Ford Fusion MOT tests in this dataset passed — a 28.1% fail rate.
What is the most common MOT failure on a 2003 Ford Fusion?
Lighting & signalling, recorded in 20.1% of tests, followed by brakes (12.2%).
Does the 2003 Fusion get worse with mileage?
Its MOT fail rate rises from 18.9% in the 0-30k band to 32.4% in the 150k+ band.
Methodology & source. Based on 31,064 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.