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Peugeot 407 Problems & Known Issues

The most common Peugeot 407 problems ranked by severity — what to watch for, what it costs to fix, and what happens if you ignore it.

Generations

407 — Single Generation
2004–2011
1.6 HDi, 2.0 HDi, 2.0, 2.2 HDi, 2.2, 2.2

Top issues to watch for

The most serious Peugeot 407 problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.

Major
Front suspension lower arm bushes premature wear (407)
4072004–201140k–120k miles
The front suspension lower arm bushes on the 407 fail significantly earlier than typical for this class of vehicle, with MOT data showing failure rates up to 64.1 times the national average on some variants. The rubber compounds degrade prematurely, causing excessive play in the suspension geometry. This affects steering precision, tyre wear patterns, and vehicle stability. The issue appears across all engine variants and worsens over time.
What happens if ignoredWorn suspension bushes cause unpredictable handling, particularly during emergency manoeuvres or heavy braking. Tyre wear accelerates significantly, with premature replacement needed. If left unrepaired, the suspension geometry becomes increasingly unstable and will fail MOT testing.
Independent garage
£200–£350
Specialist
£250–£400
Main dealer
£400–£600
Parts only
£80–£150
Major
Electronic system warning light malfunctions (407)
4072004–201140k–150k miles
The 407 suffers from widespread electronic system malfunctions that trigger persistent warning lights on the dashboard, with MOT data showing failure rates up to 57.6 times the national average. These range from ABS and ESP system faults to engine management and airbag warnings. The failures often relate to corroded wiring, failed sensors, or ECU software corruption rather than actual component failures.
What happens if ignoredActive warning lights will cause MOT failure and may indicate serious safety system malfunctions. Diagnostic costs accumulate as multiple scans are often needed to isolate intermittent faults. Some electronic faults put the vehicle into limp mode, severely limiting performance and drivability.
Independent garage
£150–£400
Specialist
£200–£500
Main dealer
£300–£800
Parts only
£50–£300
Major
Diesel particulate filter blockage (407 HDi)
4071560, 1997, 21792004–201160k–150k miles
All diesel 407 variants suffer from DPF blockage issues, with MOT smoke opacity failures running at 33.4 times the national average on 1.6 HDi models. The DPF system was relatively early technology on this generation and struggles with frequent short journeys or stop-start driving. Blocked filters cause excessive smoke emissions, reduced power, and eventual limp mode activation.
What happens if ignoredA completely blocked DPF requires expensive replacement, typically costing £1,500-£2,500. Attempts to clear blockages with aggressive regeneration can damage other engine components. The car will fail MOT testing on emissions and may become undriveable if the engine enters permanent limp mode.
Independent garage
£200–£2,000
Specialist
£300–£2,200
Main dealer
£400–£2,500
Parts only
£800–£1,800
Major
Brake caliper seizure and binding (407)
4072004–201180k–150k miles
The 407 suffers from brake caliper seizure at rates significantly above the national average, with MOT data showing binding brake failures up to 11.2 times typical levels. The caliper pistons and sliding pins corrode and seize, causing uneven braking, premature pad wear, and potential brake fade. This particularly affects the rear calipers where corrosion protection is less effective.
What happens if ignoredSeized brake calipers cause dangerous uneven braking that can lead to loss of control, particularly in emergency stops. Binding brakes increase fuel consumption, cause premature tyre wear, and can lead to brake disc warping or complete brake failure if the system overheats.
Independent garage
£150–£300
Specialist
£200–£400
Main dealer
£300–£600
Parts only
£80–£200

1 more known issues tracked

Including wear items, electrical niggles, and generation-specific problems. Check a specific car to see which issues apply to its age and mileage.

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MOT failure hotspots

Based on DVSA MOT test data. These are the items where the Peugeot 407 fails at a significantly higher rate than the average car.

Emissions failure
Exhaust & Emissions · 0-20k miles
MOT failure rate: 152x the fleet average
Sample: 373 tests
Suspension pin, bush or joint worn
Suspension · 0-20k miles
MOT failure rate: 68x the fleet average
Sample: 449 tests
Anti-roll bar links worn
Suspension · 0-20k miles
MOT failure rate: 64x the fleet average
Sample: 837 tests
ABS fault
Brakes · 0-20k miles
MOT failure rate: 59x the fleet average
Sample: 714 tests
Headlight fault
Lights & Electrics · 0-20k miles
MOT failure rate: 42x the fleet average
Sample: 517 tests
Transmission shaft constant velocity joint boot...
Bodywork · 0-20k miles
MOT failure rate: 26x the fleet average
Sample: 1,034 tests

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Related

Peugeot 407 reliability FAQs

What are the most common problems with the Peugeot 407?

The Peugeot 407 has 5 known issues across 2 severity levels. The most common problems relate to Front suspension lower arm bushes premature wear (407) and Electronic system warning light malfunctions (407).

Is the Peugeot 407 reliable?

The Peugeot 407 has 0 dangerous and 4 major known issues. No dangerous issues are tracked, which is a positive sign.

How much does it cost to fix Peugeot 407 problems?

Repair costs range widely. The most significant issue (Front suspension lower arm bushes premature wear (407)) costs £200–£350 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.