2002 Ford Fusion: common problems and what to check
What gets flagged at MOT on 2002 Ford Fusions, from 393 tests in 2025, plus known faults and what to look at before you buy one.
Small sample: only 393 of these were MOT tested in 2025, so treat the percentages as rough. The known faults below don't depend on it.
What stands out
Parts flagged at MOT more often on 2002 Ford Fusions than on all cars registered in 2002.
- Headlights1.8× usualFord Fusion19.8% All 2002 cars10.8%
Failed outright at MOT: 6.9%, against 4% of all 2002 cars. The rest were advisories or minor defects.
Rough price £40–£400 our estimateAt the viewing: Check both headlights on dipped and full beam, and look for cloudy or cracked lenses.
- Brake lights2.5× usualFord Fusion14% All 2002 cars5.7%
Failed outright at MOT: 11.7%, against 4.6% of all 2002 cars. The rest were advisories or minor defects.
Rough price £10–£80 our estimateAt the viewing: Ask a friend to check every light while you work the switches: indicators, brake lights, fog lights and reversing lights.
- Brakes pulling to one side3.8× usualFord Fusion8.7% All 2002 cars2.3%
Failed outright at MOT: 7.4%, against 1.7% of all 2002 cars. The rest were advisories or minor defects.
Rough price £100–£350 our estimateAt the viewing: On a quiet road, brake firmly from about 30mph. The car should stop straight without pulling.
- Ball joint dust cover2.4× usualFord Fusion10.4% All 2002 cars4.3%
Failed outright at MOT: 2.3%, against 1.5% of all 2002 cars. The rest were advisories or minor defects.
Rough price £60–£150 (one joint) ClickMechanicAt the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.
By area
The share of 2002 Ford Fusion MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.
- Lights and electrics49% of testsRough price £10–£80
At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.
- Suspension46% of testsRough price £120–£400
At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.
- Brakes45% of testsRough price £150–£350
At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.
- Tyres34% of testsRough price £70–£150
At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.
- Oil and fluid leaks18% of testsRough price £80–£600
At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.
- Wipers, windscreen and mirrors12% of testsRough price £15–£250
At the viewing: Check for chips in the driver's view, and test the wipers and washers.
Known faults
Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.
- Water leaking into the cabinAll engines
Faulty pollen filter seals can let water into the cabin.
At the viewing: Feel the front carpets for damp.
- Diesel pipework faultsDiesel
Some turbodiesels have had faulty pipework.
At the viewing: Look for leaks and check for lost power.
Looking at a Ford Fusion?
Check the actual car: its own MOT history, mileage and what to ask the seller. Free, no sign-up.
Other years
| Year | MOT tests | Most flagged |
|---|---|---|
| 2012 | 772 | Lights and electrics 32% |
| 2011 | 2,445 | Lights and electrics 34% |
| 2010 | 5,439 | Brakes 38% |
| 2009 | 7,860 | Brakes 38% |
| 2008 | 7,171 | Brakes 40% |
| 2007 | 6,449 | Brakes 42% |
| 2006 | 5,757 | Lights and electrics 48% |
| 2005 | 3,866 | Brakes 47% |
| 2004 | 3,339 | Suspension 47% |
| 2003 | 2,978 | Brakes 48% |
Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2002 Ford Fusions registered in 2002. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score