2004 Vauxhall Vivaro — MOT failures & pass rate
The 2004 Vauxhall Vivaro passed 66.9% of its 32,566 recorded MOT tests. That is 3.2 percentage points worse than vans of a similar age, which fail at 29.9%. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
No single area dominates — lighting & signalling (22.4%) and suspension (20.0%) are close, so failures are spread across several systems rather than one weak point.
At component level the recurring items are ball joint, position lamp and track rod end — ball joint alone was recorded 3,734 times.
Condition tracks the odometer closely. Failures run at 37.6% in the 0-30k band and 33.4% in the 150k+ band, a 4.2-point spread.
Brakes is the most common advisory, noted on 40.5% of tests — work that passed today but is likely due soon.
The trend is improving — the fail rate fell from 33.8% in 2021 to 31.9% in 2025, as the worst-kept examples leave the fleet.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 22.4% | 7,289 |
| 2 | Suspension | 20.0% | 6,522 |
| 3 | Brakes | 17.1% | 5,563 |
| 4 | Visibility | 10.4% | 3,396 |
| 5 | Steering | 9.1% | 2,976 |
| 6 | Body, structure & corrosion | 7.8% | 2,547 |
Most common specific failures
The exact components most often recorded as failures — more specific than the categories above.
| # | Failure item | Times recorded |
|---|---|---|
| 1 | Ball joint | 3,734 |
| 2 | Position lamp | 2,945 |
| 3 | Track rod end | 2,931 |
| 4 | Headlamp aim | 2,776 |
| 5 | Rbt (sp) | 2,675 |
| 6 | Washers | 2,434 |
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 | 40.5% | 13,192 |
| 2 | Suspension | 38.1% | 12,411 |
| 3 | Emissions & environmental | 27.3% | 8,889 |
| 4 | Tyres | 24.9% | 8,122 |
| 5 | Other defects | 22.7% | 7,386 |
| 6 | Lighting & signalling | 15.4% | 5,010 |
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 | 133 | 37.6% |
| 30-60k | 251 | 26.7% |
| 60-90k | 1,426 | 29.9% |
| 90-120k | 4,882 | 32.0% |
| 120-150k | 8,349 | 33.7% |
| 150k+ | 17,310 | 33.4% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Diesel | 32,421 | 33.1% |
| Petrol | 144 | 36.1% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 8,678 | 33.8% |
| 2022 | 7,654 | 33.3% |
| 2023 | 6,584 | 32.8% |
| 2024 | 5,350 | 32.8% |
| 2025 | 4,300 | 31.9% |
What to check before buying a 2004 Vivaro
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 22.4% of tests. Start there.
- Lighting & signalling (22.4% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (20.0% 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 (17.1% 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 Vauxhall Vivaros pass their MOT?
66.9% of the 32,566 2004 Vauxhall Vivaro MOT tests in this dataset passed — a 33.1% fail rate.
What is the most common MOT failure on a 2004 Vauxhall Vivaro?
Lighting & signalling, recorded in 22.4% of tests, followed by suspension (20.0%).
Does the 2004 Vivaro get worse with mileage?
Its MOT fail rate rises from 37.6% in the 0-30k band to 33.4% in the 150k+ band.
Methodology & source. Based on 32,566 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.