Ford Fusion common problems and MOT pass rate

In 2025, DVSA recorded 46,353 initial MOT tests on the Ford Fusion in Great Britain, and 57.8% passed first time. Here is where the rest failed.

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Ford Fusion at the MOT, 2025

Initial MOT tests: 46,353
Passed first timeAll cars and vans: 72.1%: 57.8%
Failed at firstIncluding 10.1% repaired at the test and passed (PRS): 42.2%
Had a dangerous defectAll cars and vans: 7.3%: 8.5%
Licensed in the UKEnd of 2026 Q2, plus 5,806 off the road (SORN): 39,543

Contains DVSA MOT data, Open Government Licence v3.0, year 2025.

Failure areas

Where the Fusion fails its MOT

The share of initial tests in 2025 with at least one fail or PRS item in each part of the MOT. A test can fail in more than one area, so these do not add up to the fail rate.

1Lamps, reflectors and electrical equipment
24.4%
Headlamps and their aim, brake lights, indicators, fog and reversing lamps, warning lights, battery and wiringAll cars and vans: 10.8%
2Suspension
13.5%
Springs, shock absorbers, suspension arms and bushes, anti-roll bars, wheel bearings and axlesAll cars and vans: 9.0%
3Brakes
11.5%
Pedal and handbrake, pipes and hoses, discs, pads and drums, and how well the car stopsAll cars and vans: 6.4%
4Body, chassis and structure
6.7%
Corrosion and damage to the structure, the exhaust system, fuel system, doors, seats, towbar, bumpers and engine mountingsAll cars and vans: 3.3%
5Visibility
6.7%
The driver's view, windscreen damage, wipers, washers and mirrorsAll cars and vans: 4.4%
6Tyres
5.9%
Tread depth, cuts and bulges, the right size and type, valves and tyre pressure warning systemsAll cars and vans: 6.2%
7Noise, emissions and leaks
5.4%
Exhaust emissions and smoke, exhaust noise and fluid leaksAll cars and vans: 3.2%
8Steering
3.1%
Steering rack, joints and linkages, power steering, the steering wheel and columnAll cars and vans: 2.0%
9Seat belts and airbags
0.8%
Seat belts, airbags and the airbag warning lightAll cars and vans: 1.0%
10Registration plates and VIN
0.4%
Number plates and the vehicle identification numberAll cars and vans: 0.3%

This modelAll cars and vans

Parts

The parts that fail most

Share of initial tests with a fail or PRS item on each part, 2025.

Stop lampLamps and electrics9.5%
Headlamp aimLamps and electrics5.9%
Rigid brake pipesBrakes5.5%
Position lampsLamps and electrics5.4%
Exhaust emissionsEmissions and leaks5.1%
Front and rear fog lampsLamps and electrics5.0%
Brake performanceBrakes4.9%
Suspension armsSuspension4.8%

By age

Pass rate by year first used

Older cars fail more often, so compare a car with others of its year. Cars up to 25 years old; years with fewer than 250 tests are left out.

First used	Tests	Passed first time	Dangerous defect
2012	774	68.0%	5.6%
2011	2,438	66.7%	6.4%
2010	5,423	61.3%	8.4%
2009	7,836	59.8%	7.9%
2008	7,150	58.2%	9.1%
2007	6,421	56.8%	8.8%
2006	5,735	52.4%	9.6%
2005	3,850	55.8%	8.7%
2004	3,325	54.4%	8.6%
2003	2,965	53.9%	8.5%
2002	396	52.8%	8.3%

Mileage

Fusion mileage by age

The median reading at the test: half the cars of that age had covered more, half less. Estimated from 1,000-mile bands, for cars up to 25 years old.

A car well above or below the typical figure is not a problem in itself, but the readings should rise steadily from one MOT to the next. A fall, or a long gap, is worth asking about.

Check a car's mileage record

Age at test	Median mileage	Readings
12 years	59,500 miles	294
13 years	67,300 miles	1,752
14 years	73,100 miles	3,817
15 years	77,500 miles	7,103
16 years	81,800 miles	7,081
17 years	86,100 miles	6,793
18 years	89,600 miles	6,049
19 years	93,300 miles	4,706
20 years	94,500 miles	3,575
21 years	97,500 miles	3,147
22 years	96,200 miles	1,651

Checking a particular Fusion?

Averages tell you what to look at. The registration tells you about this car: every MOT since 2005 with its failures and advisories, each mileage reading, and whether it is taxed.

Questions

Ford Fusion: common questions

Contains DVSA MOT data, Open Government Licence v3.0, year 2025.

What is the most common MOT failure on the Ford Fusion?

In DVSA's 2025 test records, the area that failed most often on the Ford Fusion was lamps, reflectors and electrical equipment: 24.4% of initial tests had at least one fail or PRS item there, against 10.8% for all cars and vans. Next came suspension (13.5%) and brakes (11.5%).

What is the MOT pass rate for the Ford Fusion?

57.8% of 46,353 initial MOT tests on the Ford Fusion in 2025 were a pass first time. Another 10.1% passed after small repairs made at the test station within the hour (PRS). Across all cars and vans, 72.1% passed first time.

Does a lower pass rate mean the Ford Fusion is unreliable?

Not on its own. MOT results depend on age, mileage and upkeep as much as on design, so a model with many older cars on the road will usually fail more often. The table by year compares cars of a similar age. What matters most is the record of the car you are looking at, so check its MOT history before you buy.

What counts as a dangerous defect?

One the tester judges to be a direct and immediate risk to road safety, or to have a serious impact on the environment. The car fails and should not be driven until it is repaired. 8.5% of initial tests on the Ford Fusion found at least one, against 7.3% for all cars and vans.

Where do these figures come from?

From DVSA's anonymised MOT test data for 2025, published under the Open Government Licence. We count initial tests on cars and light vans in Great Britain, as DVSA does in its own statistics: retests, appeals and abandoned tests are left out, and so are advisories and minor defects.

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