Common problems

Ford Fusion body and structure problems

How often MOT testers find body and structure faults on the Ford Fusion at each age, against all cars of the same age, and which items come up most. From 220,682 DVSA MOT tests taken 2022 to 2025.

MOT data updated 28 September 2026

At 16 years, the most tested age

Body and structure fails per 100 MOTs (n=32,396)6.5

All cars at 16 years (n=4,858,625)7.6

Body and structure advisories and minor defects per 100 MOTs (n=32,396)9.5

All cars, same age (n=4,858,625)12.6

What stands out

At 16 years, 6.5 of every 100 MOTs of the Ford Fusion found a body and structure fail (n=32,396), against 7.6 for all cars of that age (n=4,858,625).
It is level with or below the all-car rate at every age with at least 1,000 tests.
The gap is widest at 22 years: 6.5 per 100 MOTs against 9.4 for all cars.
The body and structure fail item recorded most often at 16 years: driveshaft CV boot split, on 2.6 per 100 MOTs.
The most common body and structure advisory or minor defect: exhaust system: has a minor leak of exhaust gases, on 3.9 per 100 MOTs.

Body and structure fails by age

Solid line: this model. Dashed line: all cars at the same age.

Ford Fusion: body and structure fails and advisories per 100 MOTs, by age, against all cars. Ages with fewer than 1,000 tests are not shown.
Age	Tests (n)	Fails	All cars	Advisories	All cars
11 years	3,486	2.4	3.5	2.9	5.1
12 years	9,548	3.6	4.3	4.1	6.5
13 years	18,779	4.2	5.0	5.7	8.0
14 years	26,506	5.4	5.9	7.3	9.7
15 years	31,431	6.1	6.7	8.6	11.2
16 years	32,396	6.5	7.6	9.5	12.6
17 years	28,279	7.1	8.3	10.3	13.9
18 years	24,492	7.3	8.7	11.3	14.7
19 years	21,014	6.7	9.0	11.5	15.2
20 years	13,464	6.9	9.2	12.0	15.6
21 years	7,769	6.9	9.3	12.7	16.0
22 years	3,518	6.5	9.4	10.6	16.3

Body and structure fail items at 16 years

Body and structure fail items on the Ford Fusion at 16 years (n=32,396), per 100 MOTs, with all cars at the same age (n=4,858,625).
Item	Per 100 MOTs	All cars	Typical repair (estimate)
Driveshaft CV boot split	2.6	2.9	£88 to £196 per boot (rough guide)
Exhaust system: has a major leak of exhaust gases	1.8	1.8	£182 to £263 per section

Body and structure advisories and minor defects at 16 years

Advisories and minor defects are recorded, but the car still passes. Across all cars, a part with an advisory or minor defect failed at the next MOT 5.5 times in 100 (n=88,666,940 pairs of consecutive MOTs), against 0.3 times in 100 when the same part had none (n=12,936,860,350).

Body and structure advisories and minor defects on the Ford Fusion at 16 years (n=32,396), per 100 MOTs, with all cars at the same age (n=4,858,625).
Item	Per 100 MOTs	All cars	If it needs replacing (estimate)
Exhaust system: has a minor leak of exhaust gases	3.9	4.6	£182 to £263 per section
Drive shaft joints: constant velocity boot severely deteriorated	2.0	3.5

Repair estimates are a guide for an independent garage: labour at the national median local garage rate (median £78 an hour from 65 garages, ONS price quotes) times estimated labour hours, plus a parts band. Labour hours and most parts bands are estimates, not quotes, and prices vary by model, engine and region. A warning light fault shows the cost of the diagnosis only.

What to check on a viewing

On the Ford Fusion, the body and structure items testers fail most are driveshaft CV boot split; exhaust system: has a major leak of exhaust gases.

Look underneath at the sills, floor, subframes and jacking points for corrosion, or for fresh underseal that may hide it.
Check that doors, bonnet and boot open, close and latch properly.
Look for loose trim, sharp edges or damage around the bumpers and wheel arches.

Ask for the car's MOT history: a body and structure advisory that repeats from year to year has not been fixed. GOV.UK MOT history.

Questions

What are the common body and structure problems on the Ford Fusion?

At 16 years (32,396 MOTs), the body and structure fail items testers record most often are driveshaft CV boot split (2.6 per 100 MOTs), exhaust system: has a major leak of exhaust gases (1.8 per 100 MOTs). The most common body and structure advisories or minor defects are exhaust system: has a minor leak of exhaust gases (3.9) and drive shaft joints: constant velocity boot severely deteriorated (2.0).

Does the Ford Fusion have more body and structure problems than other cars?

At 16 years it has 6.5 body and structure fails per 100 MOTs against 7.6 for all cars of the same age (1.1 fewer). It is level with or below the all-car rate at every age with enough tests.

What does a body and structure repair cost on the Ford Fusion?

For driveshaft CV boot split, an independent garage estimate is £88 to £196 per boot (rough guide). This is a guide built from the national median garage labour rate and estimated labour hours, not a quote.

Body and structure problems on other Ford models

Read this with care. A fail rate is not a measure of build quality. How far cars are driven, how they are used and how well owners maintain them all change it, and wear items such as tyres and brake pads are common fails. Compare a model only with cars of the same age. Methodology and limits.

The all cars figures cover all class 4 vehicles (cars and light vans) tested at the same age.

Looking at a Ford Fusion?

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Repair estimates: ONS consumer price quotes for local garage labour (09/2025 to 08/2026), the MOT inspection manual for defect wording, and estimated labour hours and parts bands. Not affiliated with or endorsed by ONS.

Source

Contains public sector information licensed under the Open Government Licence v3.0. Source: DVSA anonymised MOT test data, class 4 normal MOT tests, 2022 to 2025. MOT data updated 28 September 2026.

Not affiliated with or endorsed by DVSA. How we calculate these figures · Data sources