2006 Ford Fusion — MOT failures & pass rate
49,101 MOT tests on the 2006 Ford Fusion are in this dataset, and 73.4% of them passed. Superminis of a similar age fail 28.4% of the time, so this is 1.8pp 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 21.1% of all tests — 10.1 points clear of suspension, so it is the first thing to check.
At component level the recurring items are headlamp aim, stop lamp and headlamp — headlamp aim alone was recorded 4,484 times.
Mileage is the strongest signal on the record: 14.8% of 0-30k cars fail, rising to 34.3% once past 150k — 2.3× the risk.
Split by fuel, diesel examples fail 2.4pp more often than petrol ones (28.5% vs 26.0%) — worth weighing if you have a choice.
Advisories point at the next bill rather than this one: brakes was flagged on 36.7% of tests without failing them.
The trend is worsening — 25.7% of tests failed in 2021 against 28.2% in 2025, the usual pattern as a fleet ages.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 21.1% | 10,341 |
| 2 | Suspension | 10.9% | 5,362 |
| 3 | Brakes | 10.2% | 4,994 |
| 4 | Visibility | 5.5% | 2,722 |
| 5 | Body, structure & corrosion | 5.5% | 2,686 |
| 6 | Tyres | 5.0% | 2,455 |
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 | 4,484 |
| 2 | Stop lamp | 4,018 |
| 3 | Headlamp | 3,929 |
| 4 | Rigid brake pipes | 3,588 |
| 5 | Position lamp | 2,259 |
| 6 | Wipers | 2,254 |
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 | 36.7% | 18,010 |
| 2 | Tyres | 29.0% | 14,224 |
| 3 | Suspension | 28.7% | 14,102 |
| 4 | Lighting & signalling | 20.4% | 10,011 |
| 5 | Other defects | 14.2% | 6,993 |
| 6 | Emissions & environmental | 12.5% | 6,117 |
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 | 860 | 14.8% |
| 30-60k | 8,215 | 19.7% |
| 60-90k | 16,422 | 24.9% |
| 90-120k | 14,397 | 29.6% |
| 120-150k | 6,658 | 31.5% |
| 150k+ | 2,528 | 34.3% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 37,800 | 26.0% |
| Diesel | 11,301 | 28.5% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 11,875 | 25.7% |
| 2022 | 10,796 | 25.5% |
| 2023 | 10,002 | 27.0% |
| 2024 | 8,831 | 27.3% |
| 2025 | 7,597 | 28.2% |
What to check before buying a 2006 Fusion
On a 2006 Fusion, lighting & signalling is what the MOT record says goes wrong most — it appeared in 21.1% of tests. Check these areas before you commit.
- Lighting & signalling (21.1% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (10.9% 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 (10.2% 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 2006 Ford Fusions pass their MOT?
73.4% of the 49,101 2006 Ford Fusion MOT tests in this dataset passed — a 26.6% fail rate.
What is the most common MOT failure on a 2006 Ford Fusion?
Lighting & signalling, recorded in 21.1% of tests, followed by suspension (10.9%).
Does the 2006 Fusion get worse with mileage?
Its MOT fail rate rises from 14.8% in the 0-30k band to 34.3% in the 150k+ band.
Methodology & source. Based on 49,101 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.