Ford Fusion (2004)
2004 Ford Fusion
CarHunch analysed 15,288 real MOT records for the 2004 Ford Fusion. This breakdown of actual test outcomes — pass rates, defect profiles, mileage data — isn't published anywhere else.
The 2004 Ford Fusion falls short of the UK average with a 76.3% first-time pass rate, and one in three of these cars have recorded a dangerous defect at some point, which is a significant concern for a buyer. Petrol models fare slightly better at 76.8% pass rate versus 74.6% for diesels, though neither inspires confidence.
At around 60,000 miles median, these Fusions have been run relatively gently for their age, yet they're averaging 4.6 failures per MOT test—well above what you'd expect from a well-maintained example. The 23 advisories per vehicle suggest widespread wear across multiple systems rather than isolated problem areas, so budget for repairs beyond the obvious and check the full MOT history carefully before committing.
Petrol vs Diesel
Pass rate difference of 2.2 percentage points — worth knowing if you're choosing between the two.
What to check before buying a 2004 Ford Fusion
Practical pre-purchase checks for this age and model.
- 📋 Check the full MOT history. Look for recurring advisories — slow-building issues like corrosion or brake wear patterns show up years before they become failures. Enter the reg below for a full AI analysis.
- 🔍 Inspect for corrosion in person. Brake pipes, sills, subframes, and chassis legs. Surface rust is normal at this age; structural rust is a serious problem that's expensive to fix and can fail an MOT.
- 🛞 Check tyres and brakes. The most common advisory items at this age. Budget for replacement if they're near the limit — factor this into your offer price.
- ⚠️ 33.3% of these vehicles have had a dangerous defect recorded. Enter the reg below — the full MOT history will show exactly what was flagged and whether it was resolved.
- 📄 Run an HPI check. The MOT history won't show outstanding finance, insurance write-offs, or stolen status — an HPI check will.
Before you buy a Ford Fusion
MOT history is one piece of the puzzle. These checks can reveal what CarHunch can't.
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Pass Rate by Fuel Type
| Fuel type | Vehicles | Pass rate | Avg failures |
|---|---|---|---|
| Petrol (76%) | 11,592 | 76.8% | 4.48 |
| Diesel (24%) | 3,692 | 74.6% | 4.94 |
| LPG (0%) | 2 | 78.1% | 3.5 |
| Other (0%) | 2 | 64% | 6.5 |
Mileage Distribution
Most 2004 Ford Fusion vehicles sit in the blue band. If the car you're looking at is outside it, it's either unusually low or high mileage for its age.
Half of all 2004 Ford Fusion vehicles fall between 45,811 and 75,525 miles.
2004 Ford Fusion — Still on the Road
Numbers are declining — 3,223 vehicles still getting MOTs in 2025 (23% of peak).
Based on vehicles from this manufacture year that had at least one MOT test in each calendar year. Data from 2014–2025.
MOT History Averages
Most Common MOT Issues — 2004 Ford Fusion
Based on actual MOT test records for this model. Percentage shows how often each item appears across all vehicles in this cohort.
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72%
Nearside Front Tyre worn close to the legal limit
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64%
Offside Front Tyre worn close to the legal limit
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61.3%
Nearside Rear Tyre worn close to the legal limit
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48.2%
Offside Rear Tyre worn close to the legal limit
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44.6%
Oil leak, but not excessive
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40.4%
Offside Front Brake pipe corroded, covered in grease or other material
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36.3%
Offside Rear Brake pipe corroded, covered in grease or other material
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32.4%
Nearside Front Tyre worn close to legal limit/worn on edge
Data covers a 3-year window centred on 2004. Counts include advisories and failures.
Found a specific Ford Fusion?
Enter the reg to see its individual MOT history, AI Hunches, and how it compares to this cohort.