2004 Ford Fusion: common problems and what to check
What gets flagged at MOT on 2004 Ford Fusions, from 3,339 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 2004 Ford Fusions than on all cars registered in 2004.
- Rigid brake pipes2× usualFord Fusion34.2% All 2004 cars17.1%
Failed outright at MOT: 7.2%, against 2.7% of all 2004 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.
- Ball joint dust cover2.3× usualFord Fusion10.9% All 2004 cars4.8%
Failed outright at MOT: 3.9%, against 1.8% of all 2004 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× usualFord Fusion11.4% All 2004 cars5.7%
Failed outright at MOT: 8.8%, against 4.4% of all 2004 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.
- Steering swivel joints4.9× usualFord Fusion5.4% All 2004 cars1.1%
Failed outright at MOT: 1%, against 0.1% of all 2004 cars. The rest were advisories or minor defects.
Rough price £100–£450 our estimateAt the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.
- Transmission oil leaks1.9× usualFord Fusion3.2% All 2004 cars1.7%
Failed outright at MOT: 0%, against 0% of all 2004 cars. The rest were advisories or minor defects.
Rough price £80–£600 our estimateAt the viewing: Look under the engine and where the car is usually parked for fresh oil. Ask whether the leak has been looked at.
Suspension arm bushes and joints: 2.9% here, against 9.5% of all 2004 cars. Ball joint: 1.9% here, against 6.6% of all 2004 cars.
By area
The share of 2004 Ford Fusion MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.
- Suspension47% 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.
- Lights and electrics46% of testsRough price £10–£80
At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.
- Brakes46% 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.
- Tyres35% 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 leaks16% 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% |
| 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 2004 Ford Fusions registered in 2004. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score