Used car guide

2004 Ford Ka: common problems and what to check

What gets flagged at MOT on 2004 Ford Kas, from 1,465 tests in 2025, plus known faults and what to look at before you buy one.

1,465MOT tests in 2025
50%pass first time (all 2004 cars: 58%)
2,400typical miles a year
3.1×the usual rate for rust around suspension or steering mountings

What stands out

Parts flagged at MOT more often on 2004 Ford Kas than on all cars registered in 2004.

  • Rust around suspension or steering mountings3.1× usual
    Ford Ka
    20.7% All 2004 cars
    6.6%

    Failed outright at MOT: 12.6%, against 3% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £100–£450 our estimate

    At the viewing: On a straight road the steering wheel should sit straight. Listen for knocks when turning, and check the steering feels even.

  • Suspension arm bushes and joints2.4× usual
    Ford Ka
    23.2% All 2004 cars
    9.5%

    Failed outright at MOT: 6.3%, against 2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £120–£180 (one arm) ClickMechanic

    At the viewing: Listen for clunks over bumps and feel for the steering wandering. Worn arm bushes show as cracked rubber near the wheels.

  • Flexible brake hoses2.5× usual
    Ford Ka
    14.3% All 2004 cars
    5.7%

    Failed outright at MOT: 3.9%, against 1.2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £50–£200 our estimate

    At the viewing: Look for cracked or bulging rubber hoses behind the wheels and in the engine bay.

  • Chassis rust or damage2.4× usual
    Ford Ka
    9.7% All 2004 cars
    4%

    Failed outright at MOT: 3.8%, against 1.2% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £150–£1,000 our estimate

    At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

  • Rust in key structural areas4.6× usual
    Ford Ka
    6.4% All 2004 cars
    1.4%

    Failed outright at MOT: 4.4%, against 1% of all 2004 cars. The rest were advisories or minor defects.

    Rough price £80–£250 our estimate

    At the viewing: Pull each seatbelt sharply. It should lock, and retract cleanly.

Better than most

Ball joint: 1.6% here, against 6.6% of all 2004 cars. Drive shaft (CV) joints: 2% here, against 6.8% of all 2004 cars.

By area

The share of 2004 Ford Ka MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

  • Suspension
    52% 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.

  • Brakes
    35% 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 electrics
    34% of testsRough price £10–£80

    At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

  • Tyres
    30% 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.

  • Rust and bodywork
    25% of testsRough price £150–£1,000

    At the viewing: Check the sills, wheel arches and underneath for rust, and look along the panels for uneven gaps or paint.

  • Oil and fluid leaks
    24% 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.

Looking at a Ford Ka?

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Other years

YearMOT testsMost flagged
20199,990Tyres 25%
201810,917Tyres 28%
201713,239Tyres 29%
20168,248Suspension 36%
201513,086Suspension 48%
201418,221Suspension 48%
201318,136Suspension 52%
201216,208Suspension 55%
201115,013Suspension 56%
201016,871Suspension 57%
200915,648Suspension 59%
20083,639Suspension 55%
20072,884Suspension 57%
20062,091Suspension 56%
20051,744Suspension 53%
20031,093Suspension 58%
2002646Suspension 61%

Where this comes from: the DVSA's anonymised results for every MOT test in Great Britain in 2025, counting tests of 2004 Ford Kas registered in 2004. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score