2003 Ford Fusion: common problems and what to check
What gets flagged at MOT on 2003 Ford Fusions, from 2,978 tests in 2025, plus known faults and what to look at before you buy one.
What stands out
Parts flagged at MOT more often on 2003 Ford Fusions than on all cars registered in 2003.
- Rigid brake pipes1.8× usualFord Fusion33.6% All 2003 cars18.3%
Failed outright at MOT: 6.1%, against 2.7% of all 2003 cars. The rest were advisories or minor defects.
Rough price £100–£400 our estimateAt the viewing: Ask to see underneath, or check the MOT advisories: corroded brake or fuel pipes get worse every year and fail the MOT when they do.
- Headlights1.8× usualFord Fusion21.3% All 2003 cars12.1%
Failed outright at MOT: 6.3%, against 4.4% of all 2003 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.
- Ball joint dust cover2.5× usualFord Fusion11.8% All 2003 cars4.8%
Failed outright at MOT: 4.9%, against 1.8% of all 2003 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.
- Brake lights2.1× usualFord Fusion11.8% All 2003 cars5.7%
Failed outright at MOT: 8.9%, against 4.4% of all 2003 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 side3.2× usualFord Fusion6.3% All 2003 cars2%
Failed outright at MOT: 5.7%, against 1.5% of all 2003 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.
Suspension arm bushes and joints: 2.2% here, against 8.7% of all 2003 cars. Ball joint: 1.5% here, against 6.3% of all 2003 cars.
By area
The share of 2003 Ford Fusion MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.
- Brakes48% 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.
- Lights and electrics47% of testsRough price £10–£80
At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.
- Suspension42% 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.
- 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 leaks19% 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.
- Exhaust and emissions14% of testsRough price £100–£1,200
At the viewing: Look for black soot in the tailpipe, listen for blowing from the exhaust and check for engine or DPF warning lights.
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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% |
Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2003 Ford Fusions registered in 2003. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score