2004 Ford Tourneo — MOT failures & pass rate
The 2004 Ford Tourneo passed 67.4% of its 334 recorded MOT tests. MPVs of a similar age fail 30.1% of the time, so this is 2.5pp worse than the group it competes with. Failures cluster in lighting & signalling, suspension and body, structure & corrosion.
What the MOT record shows
No single area dominates — lighting & signalling (20.1%) and suspension (19.5%) are close, so failures are spread across several systems rather than one weak point.
At component level the recurring items are component mounting prescribed areas, chassis condition and integral vehicle structure condition — component mounting prescribed areas alone was recorded 130 times.
Mileage matters less than usual here: the 2004 Tourneo fails 34.4% of the time in the 60-90k band and 33.9% at 150k+, a spread of only 0.4 points.
Advisories point at the next bill rather than this one: brakes was flagged on 38.3% of tests without failing them.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 20.1% | 67 |
| 2 | Suspension | 19.5% | 65 |
| 3 | Body, structure & corrosion | 15.3% | 51 |
| 4 | Brakes | 12.0% | 40 |
| 5 | Visibility | 7.8% | 26 |
| 6 | Seat belts & restraints | 6.6% | 22 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Component mounting prescribed areas | 130 |
| 2 | Chassis condition | 41 |
| 3 | Integral vehicle structure condition | 31 |
| 4 | Position lamp | 25 |
| 5 | Prescribed areas | 24 |
| 6 | Headlamp aim | 22 |
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 | 38.3% | 128 |
| 2 | Suspension | 32.3% | 108 |
| 3 | Body, structure & corrosion | 26.4% | 88 |
| 4 | Tyres | 22.8% | 76 |
| 5 | Emissions & environmental | 21.9% | 73 |
| 6 | Other defects | 19.8% | 66 |
Failure rate by mileage
Higher-mileage cars tend to fail more — often the most useful guide to real condition.
| Mileage band | Tests | Fail rate |
|---|---|---|
| 60-90k | 32 | 34.4% |
| 90-120k | 57 | 28.1% |
| 120-150k | 58 | 31.0% |
| 150k+ | 165 | 33.9% |
Failure rate by age
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 85 | 31.8% |
| 2022 | 86 | 38.4% |
| 2023 | 63 | 28.6% |
| 2024 | 53 | 30.2% |
| 2025 | 47 | 31.9% |
What to check before buying a 2004 Tourneo
On a 2004 Tourneo, lighting & signalling is what the MOT record says goes wrong most — it appeared in 20.1% of tests. Check these areas before you commit.
- 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.
- Suspension (19.5% 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.
- Body, structure & corrosion (15.3% of tests): The one to take seriously on older cars — corrosion to structural areas can be costly and is an MOT failure. Typical repair: £200–£1,500+.
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 Tourneos pass their MOT?
67.4% of the 334 2004 Ford Tourneo MOT tests in this dataset passed — a 32.6% fail rate.
What is the most common MOT failure on a 2004 Ford Tourneo?
Lighting & signalling, recorded in 20.1% of tests, followed by suspension (19.5%).
Does the 2004 Tourneo get worse with mileage?
Its MOT fail rate rises from 34.4% in the 60-90k band to 33.9% in the 150k+ band.
Methodology & source. Based on 334 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.