Ford Fusion MOT Failures
An analysis of 538,567 real DVSA MOT tests on the Ford Fusion — what fails, how often, and how that compares to every other car on UK roads. Generations covered: MK1 (2002–2012).
Where the Ford Fusion fails its MOT
The single biggest MOT failure point on the Ford Fusion is emissions failure — this model is 122 times more likely to fail on this item than the average car on UK roads. That makes it an extreme outlier for anyone buying or owning this model. Across 538,567 MOT tests, 0.62% of all Ford Fusion tests recorded this as a failure.
Exhaust and emissions failures often point to catalytic converter degradation, lambda sensor faults, or — in diesel models — DPF problems. These can be expensive to fix and will cause an immediate MOT failure.
Other notable weak points include power steering fault (53x the fleet average), exhaust system damage (41x the fleet average), brake pipes corroded (56x the fleet average), and front or rear fog lamp emitted colour, position... (52x the fleet average). These ratios compare the Ford Fusion's failure rate on each item against the national average for all cars tested — a ratio of 10x means this model fails ten times more often than a typical car.
The failures span 6 categories: Exhaust & Emissions, Steering, Bodywork, Brakes, Lights & Electrics and others. If you're inspecting a Ford Fusion before purchase, these are the areas to focus on — and if any have been flagged as advisories on a previous MOT, they're likely to become failures in the near future.
How failures change with mileage
The Ford Fusion's weak points shift as the car covers more miles. Understanding these patterns helps you know what to expect — and what to budget for — at each stage of ownership.
Under 60,000 miles
At this mileage, most failures are either design-related or caused by age rather than wear. Components like bushes and drop links may not have been replaced yet, and original-fit parts can deteriorate even on low-mileage cars that spend a lot of time sitting.
For the Ford Fusion specifically, the DVSA data shows the most common failures at this mileage are emissions failure (122x the average) and brake pipes corroded (56x). power steering fault (53x) and front or rear fog lamp emitted colour, position... (52x) also appear frequently.
60,000 to 100,000 miles
This is where routine wear items start to show up. Brake components, tyres, and exhaust parts have done serious work by this point. Cars that have been well serviced will show fewer of these failures — this mileage band is where good maintenance really separates the well-kept from the neglected.
For the Ford Fusion specifically, the DVSA data shows the most common failures at this mileage are exhaust system damage (41x the average) and emissions failure (38x). coil springs broken (30x) and transmission shaft bearing worn (29x) also appear frequently.
Over 100,000 miles
High-mileage cars accumulate failures across multiple systems. The key question isn't whether things will need doing — they will — but whether the car has been maintained well enough to keep on top of them. Look for a consistent service history and recent MOT passes with minimal advisories.
For the Ford Fusion specifically, the DVSA data shows the most common failures at this mileage are emissions failure (26x the average) and axle or kingpin wear (20x). exhaust system damage (20x) and power steering fault (9.3x) also appear frequently.
Known issues beyond the MOT
An MOT only tests roadworthiness at a single point in time — it won't catch developing faults, intermittent problems, or issues that haven't yet reached the failure threshold. These are the issues that Ford Fusion specialists and owners flag most frequently, drawn from manufacturer technical bulletins, workshop data, and verified owner reports.
Brake pipe corrosion and failure Dangerous
The Fusion shows extremely high brake pipe failure rates, with MOT data indicating failures at 26 times the national fleet average. Affects MK1; typical independent garage repair cost is £150–£350.
Power steering fluid loss and pump failure Major
The Fusion suffers from widespread power steering system failures affecting the hydraulic pump, fluid reservoir, and connecting pipes. Affects MK1; typical independent garage repair cost is £250–£450.
Diesel emissions system failure (1.4 TDCi) Major
The issues stem from DPF (Diesel Particulate Filter) blockage, EGR valve carbon build-up, and fuel system contamination. Affects MK1; typical independent garage repair cost is £400–£800.
Throttle body failure and sticking Major
NHTSA data shows 537 complaints about throttle body failures on the Fusion, with symptoms including sudden loss of power, rough idling, and unintended acceleration events. Affects MK1; typical independent garage repair cost is £200–£350.
For the complete picture — including repair costs across independent, specialist, and dealer garages — see the full Ford Fusion common problems breakdown.
What to check before buying a Ford Fusion
Based on the MOT failure data and known issues above, here's what to prioritise when inspecting a Ford Fusion:
Exhaust & Emissions — check for emissions failure. Steering — check for power steering fault. Bodywork — check for exhaust system damage, transmission shaft bearing worn. Brakes — check for brake pipes corroded.
Beyond the MOT items, ask specifically about brake pipe corrosion and failure and power steering fluid loss and pump failure. These won't show up on a standard MOT but can be expensive to fix — repairs start from £150. A specialist pre-purchase inspection is worth the investment on this model.
Always check the car's full MOT history for patterns — recurring advisories often become failures within 12 months. And verify the service history to confirm maintenance has been kept up to schedule. Enter any reg into our free car check to see the complete picture.
Looking at a specific Ford Fusion?
Enter the reg to see its full MOT history, mileage records, write-off status, and finance checks.
Ford Fusion MOT FAQs
What are the most common MOT failures on a Ford Fusion?
Based on 538,567 DVSA MOT tests, the most common failure is emissions failure — at 122x the national fleet average. Other frequent failures include power steering fault and exhaust system damage.
Is the Ford Fusion reliable based on MOT data?
The Ford Fusion has 24 MOT failure categories above the fleet average. Specialists also flag brake pipe corrosion and failure as a concern. A pre-purchase inspection and service history check are recommended.
What MOT failures should I expect at high mileage?
Above 100,000 miles, the Ford Fusion most commonly fails on emissions failure and axle or kingpin wear. Under 60,000 miles, the main issues are emissions failure and brake pipes corroded.
How do I check a Ford Fusion's MOT history?
Enter the registration number into our free car check above. You'll see every MOT test result, advisories and failures, mileage readings, write-off status, and finance checks.
MOT failure data sourced from DVSA bulk test records via data.gov.uk. Ratios compare this model's failure rate against the national fleet average. Known issues sourced from manufacturer bulletins, specialist workshops, and verified owner reports.