2005 Ford Fusion — MOT failures & pass rate
Across 34,759 MOT tests, the 2005 Ford Fusion recorded a 74.2% pass rate. Superminis of a similar age fail 28.9% of the time, so this is 3.1pp better than the group it competes with. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
One area stands out: lighting & signalling, recorded in 19.3% of tests against 11.5% for the next-worst category.
At component level the recurring items are headlamp aim, rigid brake pipes and headlamp — headlamp aim alone was recorded 3,406 times.
Mileage is the strongest signal on the record: 13.3% of 0-30k cars fail, rising to 33.7% once past 150k — 2.5× the risk.
The petrol cars hold up better: 25.3% fail against 27.6% for diesel, a 2.2-point gap across 34,759 tests.
Brakes is the most common advisory, noted on 38.5% of tests — work that passed today but is likely due soon.
The trend is worsening — 25.1% of tests failed in 2021 against 26.7% in 2025, the usual pattern as a fleet ages.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 19.3% | 6,706 |
| 2 | Suspension | 11.5% | 4,012 |
| 3 | Brakes | 9.6% | 3,339 |
| 4 | Visibility | 5.8% | 2,011 |
| 5 | Body, structure & corrosion | 5.4% | 1,862 |
| 6 | Tyres | 4.9% | 1,697 |
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 | 3,406 |
| 2 | Rigid brake pipes | 3,087 |
| 3 | Headlamp | 2,769 |
| 4 | Stop lamp | 2,683 |
| 5 | Ball joint dust cover | 1,663 |
| 6 | Wipers | 1,609 |
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 | 38.5% | 13,372 |
| 2 | Suspension | 33.3% | 11,584 |
| 3 | Tyres | 29.1% | 10,119 |
| 4 | Lighting & signalling | 19.3% | 6,724 |
| 5 | Other defects | 13.5% | 4,695 |
| 6 | Emissions & environmental | 12.5% | 4,358 |
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 | 504 | 13.3% |
| 30-60k | 5,219 | 19.0% |
| 60-90k | 10,782 | 23.8% |
| 90-120k | 10,569 | 28.2% |
| 120-150k | 5,333 | 29.2% |
| 150k+ | 2,327 | 33.7% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 27,609 | 25.3% |
| Diesel | 7,150 | 27.6% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 8,885 | 25.1% |
| 2022 | 7,884 | 25.4% |
| 2023 | 6,987 | 25.6% |
| 2024 | 6,037 | 26.9% |
| 2025 | 4,966 | 26.7% |
What to check before buying a 2005 Fusion
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 19.3% of tests. Start there.
- 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 (11.5% 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 (9.6% 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 2005 Ford Fusions pass their MOT?
74.2% of the 34,759 2005 Ford Fusion MOT tests in this dataset passed — a 25.8% fail rate.
What is the most common MOT failure on a 2005 Ford Fusion?
Lighting & signalling, recorded in 19.3% of tests, followed by suspension (11.5%).
Does the 2005 Fusion get worse with mileage?
Its MOT fail rate rises from 13.3% in the 0-30k band to 33.7% in the 150k+ band.
Methodology & source. Based on 34,759 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.