Model Reports 4 min read Updated 18 Oct 2026

BMW 5 Series 2002: reliability & common MOT faults

In 2025, 67 in every 100 first MOTs on a 2002 BMW 5 Series were passes. Most common reason for a fail: Handbrake efficiency below minimum (roller test).

Summary

The 2002 BMW 5 Series follows the pattern of the model years either side.

At a glance

How 1,907 first tests went in 2025.

Passed first time
67 in every 100
Did not pass first time
33 in every 100631 failed first-attempt tests
The typical car
23 yearsabout 139,196 miles
First tests counted
1,907

What failed most often

  1. Handbrake efficiency below minimum (roller test)20 in every 100 failed tests
  2. Windscreen washers12 in every 100 failed tests
  3. Headlight aim11 in every 100 failed tests

How we count this. Data: UK MOT open data, 2025. Only Class 4 cars on their first MOT of the year are counted. A car that fails and is fixed at the test station still counts as a fail in the first-attempt rate. These are raw results, not adjusted for age, mileage, or peer mix. The MOT does not test engine or gearbox internals.

Note:

These are patterns across 2002 BMW 5 Series vehicles in 2025, not a prediction that any one car will have them. Faults are grouped by part of the car. A wear pattern follows age and use more than the way the car was built. They come from MOT defect codes, not manufacturer bulletins, recalls or a diagnosis of any one car.

Suspension

Two faults. The strongest is the suspension arm ball joint (rear): 37 times as often as on similar cars.

Figures below are measured across the 605 of 631 failed first attempts (95.9%) that recorded an odometer reading in 2025. Mileage is needed to compare like with like. 4.1% of failures are excluded because no mileage was recorded, so treat these shares as indicative for this model year.

We only list faults with at least 20 failures and a rate of about 2.0 times that of similar cars, which keeps one-off results out of the list.

Suspension arm ball joint (rear)

Failed on 21 first tests37 times as often as similar carsPossible evidence

What it means

A suspension arm ball joint is failed under the general suspension pin, bush or joint wording. Excessively worn is Major, and likely to become detached is graded Dangerous.

Anti-roll bar linkage ball joint dust cover (front)

Failed on 39 first tests2.6 times as often as similar carsPossible evidence

What it means

A suspension joint dust cover that is severely deteriorated is Minor. It becomes Major once it is missing or no longer prevents the ingress of dirt, so what matters is whether it still keeps dirt out. DVSA words this for any suspension joint dust cover, and files it here under anti-roll bars.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Steering

One fault: steering rack (front), 4.6 times as often as on similar cars.

Steering rack (front)

Failed on 44 first tests4.6 times as often as similar carsLikely evidence

What it means

Steering gear casing retaining devices dangerously loose, or visible relative movement to the chassis or bodywork, is graded Dangerous. A casing not properly attached, or fractured, is Major, but a fracture that affects the stability or attachment of the casing is Dangerous. A gaiter damaged but still keeping dirt out is Minor, and Major once missing or no longer doing so.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Brakes

Two faults. The strongest is the flexible brake hoses (rear): 3.4 times as often as on similar cars.

Flexible brake hoses (rear)

Failed on 24 first tests3.4 times as often as similar carsPossible evidence

What it means

Testers reject a flexible brake hose for being excessively damaged or chafed only if it is severe enough to expose the reinforcement. Slight damage, chafing or twisting is graded Minor. A leak is graded Dangerous on a hydraulic braking system and Major on an air system, and a hose damaged and likely to fail is also Dangerous.

Handbrake efficiency below minimum (roller test)

Failed on 118 first tests2.2 times as often as similar carsPossible evidence

What it means

A parking brake with efficiency below the minimum requirement is Major, and graded Dangerous where efficiency is less than half of the required value. On a roller brake tester, the requirement counts as met if more than half of the wheels of a brake system lock. The check applies only to vehicles whose parking brake was not already tested as the secondary brake.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Tyres

One wear pattern: tyre tread depth (rear), 2.3 times as often as on similar cars.

Tyre tread depth (rear)

Failed on 32 first tests2.3 times as often as similar carsWear pattern

What it means

Only primary grooves count when tread depth is assessed: those holding the wear indicators, or cut as deep as those when new. Shallower secondary grooves are ignored. Tread depth below the minimum for the vehicle is Dangerous, and so is a pattern not visible over the whole tread, but that second row applies only to vehicles that need the lower minimum.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Visibility

One fault: windscreen washers, 2.0 times as often as on similar cars.

Windscreen washers

Failed on 73 first tests2.0 times as often as similar carsPossible evidence

What it means

Windscreen washers that are not working, or do not provide sufficient fluid to clear the windscreen, are graded Major. They must provide enough fluid for the wipers to clear the windscreen effectively. Vehicles with an opening windscreen, or some other adequate view to the front, left and right, are not inspected for washers.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Body and structure

One fault: vehicle structure condition (rear), 2.0 times as often as on similar cars.

Vehicle structure condition (rear)

Failed on 20 first tests2.0 times as often as similar carsPossible evidence

What it means

Structure that is fractured, deformed, corroded, modified or inadequately repaired is failed on rigidity only if the overall structural rigidity of the vehicle is significantly reduced. Structure that is likely to affect steering or braking adversely is graded Dangerous. Prescribed areas are not covered here, as they are checked under other sections, including brakes and steering.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage.

Advisories

Other things testers noted as worn or close to failing, more often than on similar cars.

An advisory is a note from the tester about something that has not failed yet. It is an early warning, not a fail.

Anti-roll bar linkage ball joints (rear)

Noted on 29 first tests5.5 times as often as similar carsElevated evidence

Data: UK MOT open data, 2025. Counts cover advisories recorded on failed first tests only, compared with cars of the same age and mileage.

MOT pass rates

How first tests ended, and how the pass rates are counted.

Passed first time
67in every 100
Passed on the first test.
Fixed at the station
5in every 100
Failed, then fixed at the test station the same day.
Failed
28in every 100
Did not pass, and were not fixed at the test station.

First-attempt pass 66.9% of 1,907 first tests (2025): only cars that passed first time count. Official-style pass 71.9%: cars fixed at the test station also count as a pass. The 5 fixed and the 28 not fixed make the 33 in every 100 that did not pass first time.

Petrol and diesel

First testsPassed first time, as tested
Petrol1,25768
Diesel64464

Figures are in every 100 first tests.

Same model, other years

Passed first time in every 100, all tested in 2025.

40608010020022005201020152020Older carsNewer cars
406080100200220102020Newer cars

Newer cars are younger, so look for a jump rather than the climb. A year earlier (2024), when these cars were a year younger, 66 in every 100 passed first time.

YearPassed first timeFirst tests
199765 in every 100342
199865 in every 100644
199964 in every 100773
200067 in every 100909
200167 in every 1001,344
2002 This car67 in every 1001,907
200365 in every 1001,975
200468 in every 1002,213
200569 in every 1003,566
200668 in every 1005,221
200769 in every 1006,531
200872 in every 1005,692
200971 in every 1006,190
201073 in every 1007,321
201175 in every 10010,398
201273 in every 10012,639
201376 in every 10013,282
201481 in every 10014,992
201583 in every 10015,867
201685 in every 10014,582
201784 in every 10014,034
201886 in every 10017,248
201987 in every 10014,339
202088 in every 1007,890
202187 in every 1005,362
202286 in every 1006,182

FAQs

Short answers about how to read this model-year guide.

The 2002 BMW 5 Series follows the pattern of the model years either side. Its main cause of failure was Handbrake efficiency below minimum (roller test), about 20 in every 100 failed tests. In 2025, 66.9% of 1,907 first MOTs on the 2002 BMW 5 Series passed first time (PRS: items fixed at the station the same day, counted as a fail). The official-style rate including PRS is 71.9%. Among 631 failed first-attempt MOT tests (test year 2025), Suspension arm ball joint (rear) appears more often than on similar cars (3.5% of those tests; 21 observed failures; about 37× more often than similar cars). There is no single reliability score here; this is a pre-purchase checklist built from DVSA open data, not a guarantee for any individual car.
Ranked by how often they were actually recorded, the items that most often failed a 2002 BMW 5 Series at the first attempt were Handbrake efficiency below minimum (roller test) (19.5%), Windscreen washers (12.1%) and Headlight aim (10.9%), each as a share of the year's failed first attempts. That is what goes wrong most often on the car. The common faults table shows a different measure: faults that are unusual compared with similar cars.
Among failed first-attempt tests we highlight patterns that appear more often than on similar cars. Top example: Suspension arm ball joint (rear) (3.5% of those tests; 21 observed failures; about 37× more often than similar cars). These are statistical signals, not a diagnosis of any individual car.
Suspension arm ball joint (rear) shows up more often than on similar cars (3.5% of those tests; 21 observed failures; about 37× more often than similar cars). That does not prove a design fault. Age, mileage, and how the car was used still matter. Treat it as a pre-purchase checkpoint, not a manufacturer service bulletin.
Common MOT problem areas for the 2002 BMW 5 Series include Suspension arm ball joint (rear), Steering rack (front), Flexible brake hoses (rear). These are the faults that stand out compared with similar cars, not a complete list of what can go wrong on any individual car.
Advisories flag issues noted at the test and are not a fail rate. We show advisory patterns that appear more often than on similar cars among failed first-attempt tests, separate from common failure rows. Use them as early-warning checks, not as a pass/fail score.
This page highlights MOT failure patterns for the 2002 BMW 5 Series (registration year) using UK DVSA open data for the selected test year. Patterns are compared with cars of a similar age and mileage. It is a buyer checklist from MOT defect statistics, not a full service history or manufacturer service-bulletin list.
No. MOT tests do not cover engine internals, gearboxes, or many electronic modules. Patterns here come from MOT defect statistics only and should not be read as engine or gearbox reliability scores.

About this data

How this page is built and what it can (and can't) say.

These figures come from UK MOT open data for this model year. We surface common failure patterns against similar cars, not a full reliability score, and not a pass/fail verdict on any individual vehicle.

2024 2025

What we include

UK Class 4 cars only. Normal MOT tests (not retests); first test per vehicle per calendar year; results pass, PRS, or fail.

Same-day repairs

PRS means the car failed items that were fixed at the test station and then passed the same day. We count PRS as a first-attempt fail in headline rates so same-day repairs do not hide problems.

How we compare

We compare this model year with other Class 4 cars of similar age and mileage in the same test year. This model family is left out of the peer group so the car is not measured against itself.

What this does not cover

  • MOTs do not cover engine internals, gearboxes, or many electronics; this is not a full reliability score.
  • Common faults come from MOT defect stats, not manufacturer TSBs or recalls.
  • Age and mileage matching reduces, but does not remove, differences in how cars were used and maintained.
  • If the data for a car is too thin to say anything useful, we say so rather than guess.

Contains public sector information licensed under the Open Government Licence v3.0.

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