Fault File
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Ford Fusion

All generations and engines together · 12,922 MOT tests in the 2025 data · typical mileage at age 7: 71k

Typical mileage at age 7
71k miles
Check the mileage view below; low-mileage models can look better by age than they are.

How this model wears

Ford FusionClass average, all tracked models

Known issues

Measured

Computed from DVSA MOT results, all of Great Britain, 2025. Nothing here is opinion.

What testers flag

Share of tests where each item was recorded. The dark tick is the class average across all tracked models; bars are scaled within each group.

Faults with the car itself

The rows that judge the model rather than its keeper. 12,892 tests in this band.

Brake pipe damaged or excessively corroded
Advisory
28.9%class 6.2%
A spring or spring component fractured or seriously weakened
Advisory
11.0%class 5.0%
Fluid leaking excessively and likely to harm the environment or to pose a safety risk to other road users
Advisory
9.1%class 5.5%
Stop lamp missing, inoperative or in the case of a multiple light source more than 1/2 not functioning
Fail
8.3%class 1.8%
A suspension joint dust cover severely deteriorated
Minor
8.1%class 1.4%
Lamp emitted colour, position or intensity not in accordance with the requirements
Advisory
6.4%class 1.1%
Brake pipe damaged or excessively corroded
Fail
5.8%class 0.8%
An obligatory rear fog lamp missing, or a front or rear fog lamp inoperative or in the case of a multiple light source m
Fail
5.3%class 0.4%
A suspension component excessively damaged or corroded
Advisory
4.6%class 4.3%
A suspension joint dust cover missing or no longer prevents the ingress of dirt etc
Fail
4.2%class 0.6%

Wear, upkeep and luck

Tyres, pads and stone chips say more about how the car was driven and maintained than about how it was built.

A tyre seriously damaged
Advisory
23.0%class 9.7%
Tyre tread depth not in accordance with the requirements
Advisory
19.7%class 20.9%
Brake disc or drum excessively weakened, insecure or fractured
Advisory
11.3%class 11.4%
Number plate inscription missing or illegible
Advisory
5.3%class 2.3%
A rear registration plate lamp or light source missing or inoperative in the case of multiple lamps or light sources
Minor
4.6%class 3.3%
Wiper blade missing or obviously not clearing the windscreen
Fail
4.4%class 2.0%
A brake lining or pad worn below 1.5mm
Advisory
4.1%class 7.2%
Tyre tread depth not in accordance with the requirements
Fail
2.4%class 2.6%

Unconfirmed issues

Reported

Owner folklore from forums and the motoring press. Most of it never shows up in an MOT, which is why this section exists at all.

Front coil springs snapping

Emerging

Front coil springs corrode where they sit in the top mount cup and can snap without warning, sometimes on cars as young as three or four years old. A snapped spring end can puncture a front tyre or clonk on full lock. It shares the Fiesta's platform and parts bin, so this is the same weak point as the Mk5/Mk6 Fiesta. No formal recall was ever issued, Ford is reported to have quietly revised the mounting, but plenty of cars on the road predate that.

Reported from around 40k miles / 3-4 years · £80-150 per side to fix · sources: Honest John forum, Ford Owners Club forum

1.4 TDCi injector failure and misfires

1.4 TDCi only

The 1.4 TDCi (shared with the Fiesta and Mazda2) is prone to injector seal failure and sticking injectors, showing up as misfires, running on three cylinders, hesitation or a strong diesel smell. It tends to appear from around 80-100k miles and gets worse if the car has done mostly short journeys. Reconditioned injectors are cheaper than new but still add up if more than one has gone; expect £150-400 per injector plus diagnosis time. No recall, just a known weak point of this engine family.

Reported 80-100k miles · sources: Ford Owners Club forum (multiple threads), Honest John

Water ingress causing electrical gremlins

Emerging

Water finding its way into the engine bay or wiring connectors can corrode ignition coil packs, plug leads and multipin connectors, causing misfires, rough idling, stalling or random warning lights. One documented case involved sudden heavy steering plus oil, ignition and engine warning lights together, which cleared after a restart, traced back to corroded connectors between the ECU and fuel system. It is intermittent by nature so can be hard to pin down at a pre-purchase check.

Any age/mileage · sources: Honest John Ask HJ, Honest John owner-problem summary

Dual-mass flywheel and clutch judder on TDCi diesels

Diesel only

On the TDCi diesels the dual-mass flywheel can wear and cause juddering or vibration through the clutch pedal, worse on take-up from cold or in traffic. Garages generally recommend replacing the DMF along with the clutch rather than just the clutch on its own, since a worn flywheel will chew through a new clutch fast. A combined clutch and DMF job runs somewhere in the £400-700 bracket depending on the garage.

Reported from higher mileage cars, no fixed pattern · sources: Ford Owners Club forum, JustAnswer UK

Seized rear brakes and corroded handbrake cables

Partly in the MOT data

This is the folklore version of the measured signature fault for this class: rear caliper brackets and handbrake cables corrode, especially on cars that sit for days at a time, leaving pads stuck to discs or the handbrake dragging or barely holding on a hill. Owners report needing rear cylinders and short handbrake cables replaced as a set rather than one part at a time. It lines up with why brakes keep showing up as the class-average MOT fail point: this isn't pad wear, it's corrosion seizing moving parts that then fail an MOT brake test outright.

Any age, worse on cars used for short trips or left standing · sources: Ford Owners Club forum threads ("handbrake very poor", "braking system")

Intermittent fault on the 1.4 semi-automatic (Durashift)

Semi-automatic only

Some owners of the 1.4 semi-auto (Ford's clutchless manual/Durashift-style box, not a conventional torque-converter auto) report an intermittent fault where the box hesitates or behaves oddly, separate from the injector and coil-spring issues above. It's a minority-interest gearbox in this range and parts/specialist knowledge are thinner on the ground than for the manual, so factor that into a purchase if the car has it.

Reported by a minority of 1.4 semi-auto owners · sources: Honest John owner-problem summary

Viewing one? Ask this

Built from the two sections above.

Turn the wheel to full lock at low speed and listen for a clonk or knock from the front. A knock on lock can be a corroded coil spring about to let go, especially on cars over three or four years old.
On a diesel, watch the idle for the first few minutes and floor it briefly once warm. Hesitation, running rough, or a strong diesel smell points at 1.4 TDCi injector wear.
Wiggle the key in the ignition and check every warning light clears properly at start-up. Lights that flicker or stay on can mean corroded connectors from water ingress, not a simple bulb fault.
On a diesel with a manual clutch, pull away gently from a dead stop, cold if possible. A juddering, vibrating pedal is the dual-mass flywheel wearing out, not just clutch wear.
Apply the handbrake hard on a slope and see how many clicks it takes to hold. Needing it right up or the car creeping means a stretched or seized cable, a common MOT brake fail cause on this car.
Check the MOT history for repeated brake advisories rather than a one-off. The same brake advisory two or three years running means the corrosion issue is being patched, not fixed.
If it's the 1.4 semi-auto, drive it through several gear changes at varying throttle. Any hesitation or odd behaviour is worth a specialist look before buying, since parts knowledge for this box is scarcer.

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