2004 Vauxhall Zafira — MOT failures & pass rate
Across 41,574 MOT tests, the 2004 Vauxhall Zafira recorded a 69.8% pass rate. That is effectively the same as MPVs of a similar age (30.1% fail rate), so the MOT record here is unremarkable in either direction. Failures cluster in lighting & signalling, suspension and brakes.
What the MOT record shows
No single area dominates — lighting & signalling (15.1%) and suspension (14.5%) are close, so failures are spread across several systems rather than one weak point.
At component level the recurring items are rigid brake pipes, position lamp and coil spring — rigid brake pipes alone was recorded 4,556 times.
Mileage matters less than usual here: the 2004 Zafira fails 29.5% of the time in the 0-30k band and 33.1% at 150k+, a spread of only 3.6 points.
The petrol cars hold up better: 29.8% fail against 32.0% for diesel, a 2.3-point gap across 41,565 tests.
Brakes is the most common advisory, noted on 48.8% of tests — work that passed today but is likely due soon.
The trend is improving — the fail rate fell from 31.0% in 2021 to 28.2% in 2025, as the worst-kept examples leave the fleet.
How it compares
Top failure categories
| # | Category | % of tests affected | Tests |
|---|---|---|---|
| 1 | Lighting & signalling | 15.1% | 6,294 |
| 2 | Suspension | 14.5% | 6,043 |
| 3 | Brakes | 14.1% | 5,853 |
| 4 | Emissions & environmental | 9.2% | 3,829 |
| 5 | Body, structure & corrosion | 8.3% | 3,471 |
| 6 | Visibility | 6.5% | 2,697 |
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 | 4,556 |
| 2 | Position lamp | 2,524 |
| 3 | Coil spring | 2,393 |
| 4 | Exhaust system | 2,099 |
| 5 | Catalyst emissions | 2,062 |
| 6 | Ball joint | 2,035 |
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 | 48.8% | 20,286 |
| 2 | Suspension | 32.4% | 13,467 |
| 3 | Tyres | 30.6% | 12,728 |
| 4 | Emissions & environmental | 23.8% | 9,897 |
| 5 | Body, structure & corrosion | 19.1% | 7,930 |
| 6 | Other defects | 18.5% | 7,687 |
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 | 569 | 29.5% |
| 30-60k | 1,589 | 21.0% |
| 60-90k | 7,564 | 26.2% |
| 90-120k | 13,667 | 30.2% |
| 120-150k | 10,969 | 31.8% |
| 150k+ | 5,646 | 33.1% |
Failure rate by age
By fuel type
| Fuel | Tests | Fail rate |
|---|---|---|
| Petrol | 34,842 | 29.8% |
| Diesel | 6,723 | 32.0% |
Trend over time
| Dataset year | Tests | Fail rate |
|---|---|---|
| 2021 | 14,205 | 31.0% |
| 2022 | 10,371 | 30.1% |
| 2023 | 7,703 | 30.5% |
| 2024 | 5,468 | 28.9% |
| 2025 | 3,827 | 28.2% |
What to check before buying a 2004 Zafira
The failure pattern for this year is specific enough to inspect against: lighting & signalling accounted for 15.1% of tests. Start there.
- Lighting & signalling (15.1% of tests): Often a cheap bulb, but persistent issues can mean wiring or corrosion in the units. Typical repair: £10–£150.
- Suspension (14.5% 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 (14.1% 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 Zafiras pass their MOT?
69.8% of the 41,574 2004 Vauxhall Zafira MOT tests in this dataset passed — a 30.2% fail rate.
What is the most common MOT failure on a 2004 Vauxhall Zafira?
Lighting & signalling, recorded in 15.1% of tests, followed by suspension (14.5%).
Does the 2004 Zafira get worse with mileage?
Its MOT fail rate rises from 29.5% in the 0-30k band to 33.1% in the 150k+ band.
Methodology & source. Based on 41,574 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.