2005 Ford Fusion: common problems and what to check
What gets flagged at MOT on 2005 Ford Fusions, from 3,866 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 2005 Ford Fusions than on all cars registered in 2005.
- Rigid brake pipes2.3× usualFord Fusion34.2% All 2005 cars14.9%
Failed outright at MOT: 6.4%, against 2.4% of all 2005 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 cover2.8× usualFord Fusion13.5% All 2005 cars4.8%
Failed outright at MOT: 5.2%, against 1.8% of all 2005 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 2005 cars5.6%
Failed outright at MOT: 8.6%, against 4.3% of all 2005 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 joints4.8× usualFord Fusion5.7% All 2005 cars1.2%
Failed outright at MOT: 1.5%, against 0.2% of all 2005 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.
- Sub-frame bushes3.8× usualFord Fusion2.3% All 2005 cars0.6%
Failed outright at MOT: 0.6%, against 0.1% of all 2005 cars. The rest were advisories or minor defects.
Rough price £300–£1,000 our estimateAt the viewing: Look underneath at the frame the suspension bolts to. Flaky rust or holes are expensive to fix.
Suspension arm bushes and joints: 3.5% here, against 10.7% of all 2005 cars. Number plate lights: 2.3% here, against 8.2% of all 2005 cars.
By area
The share of 2005 Ford Fusion MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.
- Brakes47% 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.
- 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.
- Lights and electrics45% of testsRough price £10–£80
At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.
- 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 leaks15% 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.
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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% |
| 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 2005 Ford Fusions registered in 2005. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score