2004 Ford Fusion — MOT failures & pass rate
The 2004 Ford Fusion passed 73.2% of its 32,785 recorded MOT tests. Superminis of a similar age fail 29.2% of the time, so this is 2.4pp better than the group it competes with. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
Lighting & signalling dominates the failure mix at 19.3% of all tests — 7.4 points clear of suspension, so it is the first thing to check.
At component level the recurring items are rigid brake pipes, headlamp aim and headlamp — rigid brake pipes alone was recorded 3,285 times.
Mileage is the strongest signal on the record: 14.9% of 0-30k cars fail, rising to 32.7% once past 150k — 2.2× the risk.
Fuel type barely separates them — petrol fails 26.5% of the time against 27.8% for diesel.
Advisories point at the next bill rather than this one: brakes was flagged on 39.3% of tests without failing them.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 19.3% | 6,336 |
| 2 | Suspension | 11.9% | 3,909 |
| 3 | Brakes | 10.1% | 3,308 |
| 4 | Emissions & environmental | 6.0% | 1,966 |
| 5 | Visibility | 5.8% | 1,894 |
| 6 | Body, structure & corrosion | 5.4% | 1,773 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Rigid brake pipes | 3,285 |
| 2 | Headlamp aim | 3,231 |
| 3 | Headlamp | 2,663 |
| 4 | Stop lamp | 2,275 |
| 5 | Position lamp | 1,457 |
| 6 | Wipers | 1,394 |
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 | 39.3% | 12,882 |
| 2 | Suspension | 34.2% | 11,213 |
| 3 | Tyres | 29.9% | 9,794 |
| 4 | Lighting & signalling | 20.9% | 6,849 |
| 5 | Other defects | 13.6% | 4,444 |
| 6 | Emissions & environmental | 13.5% | 4,420 |
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 | 423 | 14.9% |
| 30-60k | 4,258 | 19.0% |
| 60-90k | 9,759 | 24.2% |
| 90-120k | 10,131 | 28.9% |
| 120-150k | 5,542 | 31.3% |
| 150k+ | 2,636 | 32.7% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 25,495 | 26.5% |
| Diesel | 7,281 | 27.8% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 8,951 | 26.4% |
| 2022 | 7,606 | 26.1% |
| 2023 | 6,473 | 26.7% |
| 2024 | 5,404 | 27.7% |
| 2025 | 4,351 | 27.7% |
What to check before buying a 2004 Fusion
On a 2004 Fusion, lighting & signalling is what the MOT record says goes wrong most — it appeared in 19.3% of tests. Check these areas before you commit.
- Lighting & signalling (19.3% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (11.9% 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 (10.1% 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 Ford Fusions pass their MOT?
73.2% of the 32,785 2004 Ford Fusion MOT tests in this dataset passed — a 26.8% fail rate.
What is the most common MOT failure on a 2004 Ford Fusion?
Lighting & signalling, recorded in 19.3% of tests, followed by suspension (11.9%).
Does the 2004 Fusion get worse with mileage?
Its MOT fail rate rises from 14.9% in the 0-30k band to 32.7% in the 150k+ band.
Methodology & source. Based on 32,785 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.