Ford Fusion 2003: reliability & common MOT faults

In 2025, 53 in every 100 first MOTs on a 2003 Ford Fusion were passes. Most common reason for a fail: Headlight aim.

Summary

The 2003 Ford Fusion follows the pattern of the model years either side.

At a glance

How 2,862 first tests went in 2025.

Passed first time
53 in every 100
Did not pass first time
47 in every 1001,337 failed first-attempt tests
The typical car
22 yearsabout 96,770 miles
First tests counted
2,862

What failed most often

  1. Headlight aim12 in every 100 failed tests
  2. Brake imbalance across an axle (roller test, efficiency check, rear)12 in every 100 failed tests
  3. Brake light11 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 2003 Ford Fusion vehicles in 2025, not a prediction that any one car will have them. Faults are grouped by part of the car. They come from MOT defect codes, not manufacturer bulletins, recalls or a diagnosis of any one car.

Brakes

Three faults. The strongest is the brake imbalance across an axle (roller test, efficiency check, rear): 4.7 times as often as on similar cars.

Figures below are measured across the 1,313 of 1,337 failed first attempts (98.2%) that recorded an odometer reading in 2025. Mileage is needed to compare like with like.

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.

Brake imbalance across an axle (roller test, efficiency check, rear)

Failed on 153 first tests4.7 times as often as similar carsLikely evidence

What it means

A wheel giving less than a set share of the maximum effort from the other wheel on the same axle is Major. On a steered axle, less than half is graded Dangerous. Testers disregard an imbalance if the lower effort is the result of a locked wheel, or if the higher effort from a wheel is at or below a low set figure.

Rigid brake pipes (front)

Failed on 95 first tests2.9 times as often as similar carsPossible evidence

What it means

Chafing, corrosion or damage to a rigid brake pipe justifies rejection once its wall thickness is reduced by a set amount, although DVSA accepts this is not easy to determine. If a tester is not sure, the benefit of the doubt applies. A leaking pipe or connection is graded Dangerous on a hydraulic system and Major on an air system.

Also noted as an advisory

Testers also noted it as an advisory, worn but not yet failing, on 230 first tests, 2.3 times as often as on similar cars.

Brake efficiency below minimum (roller test)

Failed on 53 first tests2.2 times as often as similar carsPossible evidence

What it means

Service brake efficiency below the minimum requirement is Major, and efficiency less than half of the required value is graded Dangerous. On a roller brake tester, if more than half of the wheels of a brake system lock, the efficiency requirement for that system counts as met.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage. Advisories count notes recorded on failed first tests only.

Suspension

Three faults. The strongest is the shock absorbers (rear): 3.8 times as often as on similar cars.

Shock absorbers (rear)

Failed on 103 first tests3.8 times as often as similar carsLikely evidence

What it means

Slight seepage that leaves a film of fluid on a shock absorber does not fail it. Severe leakage, or damage so that it does not function, is Major. A shock absorber missing or likely to become detached is graded Dangerous, though a missing one is only rejected if shock absorbers were fitted as standard.

Suspension arm ball joint dust cover (front)

Failed on 112 first tests3.3 times as often as similar carsLikely evidence

What it means

Whether a suspension arm ball joint dust cover still keeps dirt out decides its grade. Severely deteriorated is Minor, while missing, or no longer preventing the ingress of dirt, is Major.

Wheel bearings (rear)

Failed on 60 first tests3.0 times as often as similar carsLikely evidence

What it means

Excessive play in a wheel bearing, or a bearing that is excessively rough, is Major. Play so excessive that the bearing is likely to break up or directional control is impaired is Dangerous, and so is a bearing so rough that it is likely to overheat or break up.

Also noted as an advisory

Testers also noted it as an advisory, worn but not yet failing, on 50 first tests, 3.0 times as often as on similar cars.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage. Advisories count notes recorded on failed first tests only.

Lamps and electrical

One fault: individual direction indicators (front), 2.3 times as often as on similar cars.

Individual direction indicators (front)

Failed on 50 first tests2.3 times as often as similar carsPossible evidence

What it means

Direction indicators must be amber, though vehicles first used before a set date may have white at the front and red at the rear when the indicators are combined with stop or position lamps, and sequential or dynamic ones are not a reason to fail. A lamp that is missing, inoperative or has more than half of a multiple light source not functioning is graded Major. A flashing rate outside the permitted range is graded Minor.

Also noted as an advisory

Testers also noted it as an advisory, worn but not yet failing, on 61 first tests, 3.3 times as often as on similar cars.

Data: UK MOT open data, 2025. Compared with cars of the same age and mileage. Advisories count notes recorded on failed first tests only.

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. Advisories for the faults above are shown with those faults.

Brake light

Noted on 38 first tests3.0 times as often as similar carsElevated evidence

Macpherson strut (front)

Noted on 22 first tests2.5 times as often as similar carsElevated evidence

Transmission oil leaks

Noted on 54 first tests2.3 times as often as similar carsElevated evidence

Suspension mounting area (rear)

Noted on 115 first tests2.2 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
53in every 100
Passed on the first test.
Fixed at the station
10in every 100
Failed, then fixed at the test station the same day.
Failed
37in every 100
Did not pass, and were not fixed at the test station.

First-attempt pass 53.3% of 2,862 first tests (2025): only cars that passed first time count. Official-style pass 63.1%: cars fixed at the test station also count as a pass. The 10 fixed and the 37 not fixed make the 47 in every 100 that did not pass first time.

Petrol and diesel

First testsTypical mileagePassed first time, as testedPassed first time, same mileage
Petrol2,33393,624 miles5353
Diesel528111,757 miles5456

Figures are in every 100 first tests. Cars with more miles usually fail more often, so the same-mileage figure gives every fuel the mileage mix of all the cars in this year.

Same model, other years

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

40608010020032010Newer cars
40608010020032010Newer 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, 54 in every 100 passed first time.

YearPassed first timeFirst tests
200252 in every 100387
2003 This car53 in every 1002,862
200454 in every 1003,228
200556 in every 1003,722
200652 in every 1005,537
200757 in every 1006,207
200858 in every 1006,926
200959 in every 1007,606
201061 in every 1005,246
201166 in every 1002,385
201268 in every 100754

If you are buying one

What this year's MOT record means for the decision in front of you.

Mileage matters most on a 2003 Ford Fusion.

Of 2003 Ford Fusion vehicles with under 68,000 miles, 65 in every 100 passed their 2025 MOT first time. With 129,000 miles or more, 46 in every 100 did.

Under 68,000563 tests
65
68,000–88,000580 tests
55
88,000–106,000 Typical car560 tests
52
106,000–129,000564 tests
49
129,000 and over557 tests
46

Petrol or diesel?

Typical mileagePassed first time,
as tested
Passed first time,
same mileage
Petrol93,624 miles5353
Diesel111,757 miles5556

Figures are in every 100 first tests. At the same mileage there is no clear difference between the two.


What to check at your mileage

How often each fault turned up on a failed first test, by the car's mileage. Read it as: what is likely to need looking at on a car like the one in front of you.

Under 68,00088,000–106,000129,000 and over
Headlight aim3.75.97.0
Brake imbalance across an axle (roller test, efficiency check, rear)3.94.87.5
Brake light4.35.45.4
Petrol emissions (with catalyst)1.84.57.5
Suspension arm ball joint dust cover (front)2.34.56.1

Faults per 100 first tests, by the car's mileage at the test.


When a car fails

20in every 100

of failed cars had one item to fix.

61in every 100

of failed cars had three or more items to fix.

8in every 100

of all first tests had a defect the tester marked dangerous (unsafe to drive away).


Every figure here is a first-attempt MOT rate from DVSA open data for this model line, for cars of this model year tested in 2025. Each mileage band holds a fifth of the tests. MOTs do not test engine or gearbox internals, so this is a pre-purchase checklist, not a full reliability score.

FAQs

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

The 2003 Ford Fusion follows the pattern of the model years either side. Its main cause of failure was Headlight aim, about 12 in every 100 failed tests. In 2025, 53.3% of 2,862 first MOTs on the 2003 Ford Fusion passed first time (PRS: items fixed at the station the same day, counted as a fail). The official-style rate including PRS is 63.1%. Among 1,337 failed first-attempt MOT tests (test year 2025), Brake imbalance across an axle (roller test, efficiency check, rear) appears more often than on similar cars (11.7% of those tests; 153 observed failures; about 4.7× 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 2003 Ford Fusion at the first attempt were Headlight aim (12.3%), Brake imbalance across an axle (roller test, efficiency check, rear) (11.7%) and Brake light (11.3%), 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: Brake imbalance across an axle (roller test, efficiency check, rear) (11.7% of those tests; 153 observed failures; about 4.7× more often than similar cars). These are statistical signals, not a diagnosis of any individual car.
Brake imbalance across an axle (roller test, efficiency check, rear) shows up more often than on similar cars (11.7% of those tests; 153 observed failures; about 4.7× 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 2003 Ford Fusion include Brake imbalance across an axle (roller test, efficiency check, rear), Shock absorbers (rear), Suspension arm ball joint dust cover (front). 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 2003 Ford Fusion (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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