What are the most common problems with a 2002 Ford Fusion petrol?

Known faults on the 2002 Ford Fusion petrol include water leaking into the cabin. The biggest MOT weak spot is headlights: flagged on 21.2% of tests, 2× the rate for all 2002 cars, followed by coil springs (17.4%).

What should I ask the seller before buying a used 2002 Ford Fusion petrol?

Any recent work on the headlights? (Flagged at MOT 2× as often on the 2002 Ford Fusion petrol as on other cars the same age.) Any recent work on the coil springs? (Flagged at MOT 1.7× as often on the 2002 Ford Fusion petrol as on other cars the same age.) Any recent work on the shock absorbers? (Flagged at MOT 2× as often on the 2002 Ford Fusion petrol as on other cars the same age.) Can I see the service history and receipts for any big jobs?

Used car guide

2002 Ford Fusion petrol: common problems and MOT failures

What MOT testers find on the petrol Ford Fusion first registered in 2002 (petrol cars only): we looked at the 1,189 MOTs these cars had during 2023–2025. Plus known faults and what to look at before you buy one.

1,189MOTs of 2002 petrol cars, done in 2023–2025

55%pass first time (all 2002 cars: 58%)

4,200typical miles a year

2×the usual rate for headlights

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

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

Headlights2× usual

Ford Fusion
21.2% All 2002 cars
10.7%

Failed outright at MOT: 5.6%, 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.
Coil springs1.7× usual

Ford Fusion
17.4% All 2002 cars
10.2%

Failed outright at MOT: 2.6%, against 2.3% of all 2002 cars. The rest were advisories or minor defects.

Rough price £175–£400 (pair, one axle) ClickMechanic

At the viewing: Look behind each wheel for a snapped spring coil, and listen for a clunk or twang when turning the wheel lock to lock with the car stopped.
Shock absorbers2× usual

Ford Fusion
12.7% All 2002 cars
6.2%

Failed outright at MOT: 6%, against 1.5% of all 2002 cars. The rest were advisories or minor defects.

Rough price £200–£300 (pair, average rear to front) ClickMechanic

At the viewing: Push down hard on each corner. It should bounce once and settle. Look for oil on the shock absorber body.
Ball joint dust cover2.5× usual

Ford Fusion
10.2% All 2002 cars
4.1%

Failed outright at MOT: 3.5%, 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.
Brake lights2× usual

Ford Fusion
11.6% All 2002 cars
5.7%

Failed outright at MOT: 9%, against 4.7% of all 2002 cars. The rest were advisories or minor defects.

Rough price £10–£80 our estimate

At the viewing: Ask a friend to check every light while you work the switches: indicators, brake lights, fog lights and reversing lights.

Common 2002 Ford Fusion petrol MOT failures and advisories

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

Lights and electrics

47% 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

44% 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

35% 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

17% 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.
Exhaust and emissions

13% of testsRough price £100–£1,200

At the viewing: Look for black soot in the tailpipe, listen for blowing from the exhaust and check for an engine warning light.

Known faults on the 2002 Ford Fusion petrol

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

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

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

Any recent work on the headlights? (Flagged at MOT 2× as often on the 2002 Ford Fusion petrol as on other cars the same age.)
Any recent work on the coil springs? (Flagged at MOT 1.7× as often on the 2002 Ford Fusion petrol as on other cars the same age.)
Any recent work on the shock absorbers? (Flagged at MOT 2× as often on the 2002 Ford Fusion petrol as on other cars the same age.)
Can I see the service history and receipts for any big jobs?

Looking at a Ford Fusion?

Check the actual car: its own MOT history, mileage and what to ask the seller. Free, no sign-up.

Other years

Every year of the Ford Fusion compared

Year	MOT tests	Most flagged
2012	2,381	Lights and electrics 30%
2011	7,513	Brakes 31%
2010	16,986	Brakes 36%
2009	25,113	Brakes 36%
2008	23,726	Brakes 38%
2007	21,841	Lights and electrics 41%
2006	19,930	Lights and electrics 47%
2005	13,829	Brakes 45%
2004	12,392	Lights and electrics 45%
2003	11,293	Brakes 48%

Where this comes from: the DVSA's anonymised results for every MOT test done in Great Britain during 2023–2025, counting the MOTs of Ford Fusion cars first registered in 2002. "Flagged" includes advisories, so it isn't the same as a fail rate. How we score