Generations
620 — 620 Series
1993–1999
2.0 T-Series
Top issues to watch for
The most serious Rover 620 problems ranked by severity. We track 5 known issues — here are the ones you need to know about first.
Dangerous
Subframe mounting area corrosion (620)
The steel structure around suspension mounting points suffers from corrosion that compromises structural integrity. This affects the fundamental safety of the vehicle as weakened mounting points can allow suspension components to detach. The problem worsens with age and exposure to road salt, making cars from the 1990s particularly vulnerable.
What happens if ignoredIf mounting points fail completely, suspension components can detach causing immediate loss of control and a serious accident. Even partial failure affects suspension geometry, tyre wear patterns, and handling safety. Structural repairs typically require cutting out corroded sections and welding in new metal, costing £800-£1,500 per corner if caught early. Advanced corrosion may render the car uneconomical to repair.
Independent garage
£400–£800
Specialist
£600–£1,200
Parts only
£50–£150
Major
Suspension joint dust cover deterioration (620)
Rubber dust covers protecting ball joints and suspension bushes deteriorate at an exceptional rate on this model, with MOT data showing failures at 26.9x the national fleet average. Once split or missing, dirt and water ingress rapidly destroys the underlying joint or bush. This creates a cascade effect where multiple suspension components fail in quick succession, making early detection and replacement crucial for controlling repair costs.
What happens if ignoredOnce dust covers fail, the protected joint typically fails within 6-12 months depending on driving conditions. Multiple joints often need replacement simultaneously as they deteriorate at similar rates. Total suspension refresh including ball joints, drop links, and track rod ends can cost £600-£1,200. Driving with severely worn joints affects steering precision and can be dangerous.
Independent garage
£45–£85
Specialist
£55–£95
Parts only
£8–£20
Major
CV joint boot deterioration (620)
Constant velocity joint rubber boots fail at 9.6x the national fleet average according to MOT data. The boots protect the CV joints from dirt and water while retaining the special grease needed for smooth operation. Once compromised, the joints quickly develop wear leading to clicking noises and eventual failure. This is particularly problematic on the 620 due to the age of rubber components and limited availability of replacement boots.
What happens if ignoredA split boot allows grease to leak out and contaminants to enter the CV joint. The joint typically fails within 6-18 months, causing clicking noises that progress to complete failure. A failed CV joint prevents the wheel from being driven and requires recovery. Replacing just the boot costs £80-150 per side if caught early, but a worn joint requires a complete new driveshaft at £200-350 per side.
Independent garage
£80–£150
Specialist
£100–£180
Parts only
£25–£45
Minor
Exhaust system corrosion (620)
The exhaust system suffers from accelerated corrosion, failing MOT tests at 8.4x the national fleet average. The rear silencer and intermediate sections are particularly prone to rust-through from both internal moisture and external road salt exposure. Cars from the 1990s typically require partial or complete exhaust replacement during ownership, with the problem starting relatively early in the vehicle's life.
What happens if ignoredA leaking exhaust system causes noise, poor emissions performance leading to MOT failure, and potential carbon monoxide hazard if fumes enter the cabin. A complete exhaust system replacement costs £200-400 depending on specification, while individual sections can be replaced for £80-150. The car remains safe to drive with minor exhaust leaks but must be repaired for MOT compliance.
Independent garage
£120–£250
Specialist
£150–£300
Parts only
£80–£180
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.
Check a specific car →MOT failure hotspots
Based on DVSA MOT test data. These are the items where the Rover 620 fails at a significantly higher rate than the average car.
Suspension joint dust cover severely deteriorated
Suspension · 120-150k miles
MOT failure rate: 27x the fleet average
Sample: 271 tests
Suspension joint dust cover missing or no longe...
Suspension · 60-80k miles
MOT failure rate: 22x the fleet average
Sample: 213 tests
Parking brake efficiency below minimum requirement
Brakes · 40-60k miles
MOT failure rate: 19x the fleet average
Sample: 206 tests
Brake hoses perished or damaged
Brakes · 40-60k miles
MOT failure rate: 15x the fleet average
Sample: 150 tests
Seat mounting fault
Seatbelts & Airbags · 120-150k miles
MOT failure rate: 13x the fleet average
Sample: 216 tests
Steering rack wear
Steering · 150k+ miles
MOT failure rate: 12x the fleet average
Sample: 245 tests
Buying a Rover 620?
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Related
Rover 620 reliability FAQs
What are the most common problems with the Rover 620?
The Rover 620 has 5 known issues across 3 severity levels. The most serious are: Subframe mounting area corrosion (620).
Is the Rover 620 reliable?
The Rover 620 has 1 dangerous and 2 major known issues. Most can be avoided with a thorough pre-purchase check and full service history.
How much does it cost to fix Rover 620 problems?
Repair costs range widely. The most significant issue (Subframe mounting area corrosion (620)) costs £400–£800 at an independent garage. Minor issues can be under £200. Always get a full inspection before buying.