2002 Ford Fusion diesel: common problems and MOT failures

What goes wrong more than usual on a 2002 Ford Fusion diesel?

Parts flagged at MOT more often on the 2002 Ford Fusion diesel than on all cars registered in 2002.

• Rigid brake pipes2× usual
  Ford Fusion

  36.6% All 2002 cars

  18.2%

  Failed outright at MOT: 6.4%, against 2.8% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £100–£400 our estimate

  At the viewing: Ask to see underneath, or check the MOT advisories: corroded brake or fuel pipes get worse every year and fail the MOT when they do.

• Headlights2.1× usual
  Ford Fusion

  22.3% All 2002 cars

  10.7%

  Failed outright at MOT: 7%, against 4.2% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £40–£400 our estimate

  At the viewing: Check both headlights on dipped and full beam, and look for cloudy or cracked lenses.

• Ball joint dust cover2.6× usual
  Ford Fusion

  10.6% All 2002 cars

  4.1%

  Failed outright at MOT: 3.6%, against 1.5% of all 2002 cars. The rest were advisories or minor defects.

  Rough price £60–£150 (one joint) ClickMechanic

  At the viewing: Listen for knocking over bumps and check the rubber boots behind the wheels aren't split.

Common 2002 Ford Fusion diesel MOT failures and advisories

The share of 2002 Ford Fusion diesel MOT tests where testers flagged each area, as a fail or an advisory. Rough prices are typical independent-garage costs.

• Lights and electrics
  50% of testsRough price £10–£80

  At the viewing: Ask a friend to check every light, including brake lights and indicators, while you operate them.

• Brakes
  49% of testsRough price £150–£350

  At the viewing: Look for a lip on the disc edges and feel for judder or pulling when braking firmly from about 40mph.

• Suspension
  44% of testsRough price £120–£400

  At the viewing: Listen for knocks over speed bumps, and look behind each front wheel for a snapped coil spring.

• Tyres
  37% of testsRough price £70–£150

  At the viewing: Check the tread on all four tyres, including the inside edges, and look for cracks or bulges.

• Oil and fluid leaks
  21% of testsRough price £80–£600

  At the viewing: Look under the engine and on the ground where the car is usually parked for fresh oil or fluid.

• Wipers, windscreen and mirrors
  14% of testsRough price £15–£250

  At the viewing: Check for chips in the driver's view, and test the wipers and washers.

Known faults on the 2002 Ford Fusion diesel

Reported by owners, mechanics and buying guides for this model and age. Check which engine the car has, as some apply to one engine only.

• Water leaking into the cabin

  All engines

  Faulty pollen filter seals can let water into the cabin.

  At the viewing: Feel the front carpets for damp.

  Source: What Car?: used Ford Fusion (2002-2012) reliability

• Diesel pipework faults

  Diesel

  Some turbodiesels have had faulty pipework.

  At the viewing: Look for leaks and check for lost power.

  Source: What Car?: used Ford Fusion (2002-2012) reliability

Questions to ask the seller before buying a 2002 Ford Fusion diesel

Ask before you travel to see it. A seller who knows the car will have answers, and receipts.

1. Any recent work on the rigid brake pipes? (Flagged at MOT 2× as often on the 2002 Ford Fusion diesel as on other cars the same age.)
2. Any recent work on the headlights? (Flagged at MOT 2.1× as often on the 2002 Ford Fusion diesel as on other cars the same age.)
3. Any recent work on the ball joint dust cover? (Flagged at MOT 2.6× as often on the 2002 Ford Fusion diesel as on other cars the same age.)
4. Can I see the service history and receipts for any big jobs?