At a Glance
The Ford Courier has 39 identified common problems across 2 generations, with the Mk4-based (1995-2002) being the most affected generation and brakes the most common problem category. Based on 22K MOT tests from DVSA data.
Problems are patterns in the DVSA data that occur significantly more often on a specific model than the UK average — confirmed at 99% statistical confidence. Read our DVSA MOT data methodology →
Below: generation-by-generation comparison of Ford Courier common problems, MOT failure types, and pass-rate data drawn from DVSA records. Click any generation to see fuel- and engine-specific fault patterns, mileage-banded repair guidance, and the most common MOT failures testers record.
MOT Tests & Failures by Generation
Ford Courier generations by MOT tests, failures, and identified problems from DVSA data
Hover over each bar for a full breakdown. Tap any bar to view that generation's problems.
Showing total MOT tests, failures, and known problems per make. Hover over each bar for a full breakdown.
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Browse Ford Courier Generations
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Most Common Ford Courier MOT Failures
Every reason Ford Courier vehicles fail their MOT, ranked by frequency. Select an individual year to see only that year’s failures, or stay on ‘All time’ for the combined picture across our 20 years of DVSA data. Scroll inside the table for the full list.
| # | Failure | % of failures |
|---|---|---|
| 1 | Tyre tread depth below limit | 22.49% |
| 2 | Suspension joint or bush worn | 10.71% |
| 3 | Front lamp not working | 5.91% |
| 4 | Brake disc or drum worn | 5.69% |
| 5 | Brake performance below minimum | 5.17% |
| 6 | Brake hydraulic component worn | 3.11% |
| 7 | Stop lamp not working | 3.02% |
| 8 | Windscreen damage affecting view | 2.62% |
| 9 | Number plate lamp not working | 2.57% |
| 10 | Tyre condition | 2.45% |
| 11 | Brake pads or linings worn | 2.38% |
| 12 | Suspension mounting corroded | 2.09% |
| 13 | Windscreen washer not working | 1.98% |
| 14 | Parking brake condition | 1.33% |
| 15 | Wiper blades deteriorated | 1.26% |
| 16 | Exhaust system fault | 1.23% |
| 17 | Front suspension joint worn | 1.22% |
| 18 | Body corrosion or damage | 1.11% |
| 19 | Track rod end worn | 1.11% |
| 20 | Headlamp aim defect | 1.01% |
| 21 | Seat belt condition | 0.85% |
| 22 | Steering free play excessive | 0.81% |
| 23 | Rear suspension fault | 0.80% |
| 24 | Spring mounting corroded | 0.79% |
| 25 | Chassis condition | 0.74% |
| 26 | Driveshaft fault | 0.73% |
| 27 | Rear lamp not working | 0.72% |
| 28 | Fog lamp not working | 0.67% |
| 29 | Brake pedal fault | 0.53% |
| 30 | Catalytic converter efficiency low | 0.53% |
| 31 | Subframe mounting corroded | 0.49% |
| 32 | Dashboard warning lamp fault | 0.47% |
| 33 | Power steering pump fault | 0.47% |
| 34 | Front suspension fault | 0.46% |
| 35 | Suspension linkage fault | 0.44% |
| 36 | Horn not working | 0.43% |
| 37 | Shock absorber worn or leaking | 0.40% |
| 38 | Vehicle structure corrosion | 0.40% |
| 39 | Position lamp not working | 0.39% |
| 40 | Steering operation fault | 0.39% |
| 41 | Steering lock fault | 0.37% |
| 42 | Coil spring broken or corroded | 0.36% |
| 43 | Electrical switch fault | 0.36% |
| 44 | Body security fault | 0.34% |
| 45 | Battery loose or leaking | 0.33% |
| 46 | Steering column fault | 0.31% |
| 47 | Steering coupling worn | 0.31% |
| 48 | Fuel tank corroded or leaking | 0.31% |
| 49 | Brake pedal movement restricted | 0.27% |
| 50 | ABS fault | 0.26% |
| 51 | MacPherson strut worn | 0.25% |
| 52 | Axle beam corroded or cracked | 0.25% |
| 53 | Brake fluid leak | 0.25% |
| 54 | Mirror damaged or missing | 0.23% |
| 55 | Bonnet catch or hinge fault | 0.23% |
| 56 | Fuel pipe corroded or damaged | 0.22% |
| 57 | Parking brake performance below minimum | 0.22% |
| 58 | King pin or swivel pin worn | 0.22% |
| 59 | Indicator fault | 0.21% |
| 60 | Brake wheel cylinder fault | 0.21% |
| 61 | Handbrake cable fault | 0.21% |
| 62 | Fuel cap damaged or missing | 0.20% |
| 63 | Rear reflector damaged or missing | 0.20% |
| 64 | Steering arm worn | 0.20% |
| 65 | Suspension arm worn or corroded | 0.17% |
| 66 | Brake air or vacuum system fault | 0.16% |
| 67 | Rigid brake pipe corroded or damaged | 0.15% |
| 68 | Headlamp fault | 0.14% |
| 69 | Power steering pipe or hose leaking | 0.14% |
| 70 | Steering rack fault | 0.14% |
| 71 | Loading door damaged or insecure | 0.12% |
| 72 | Drag link end worn | 0.12% |
| 73 | Spare wheel fault | 0.12% |
| 74 | Airbag warning light on | 0.11% |
| 75 | CV joint worn | 0.11% |
| 76 | Tyre valve stem damaged | 0.11% |
| 77 | Brake caliper fault | 0.10% |
| 78 | Brake lever fault | 0.10% |
| 79 | Brake linkage mounting fault | 0.10% |
| 80 | Fuel hose damaged or leaking | 0.10% |
| 81 | Steering drive system fault | 0.10% |
| 82 | Tyre size or type not matched | 0.10% |
| 83 | Compression ignition emissions above threshold | 0.10% |
| 84 | Bonded suspension condition | 0.10% |
| 85 | Subframe corrosion or damage | 0.09% |
| 86 | Handbrake mechanism or mounting fault | 0.08% |
| 87 | Steering wheel damaged or insecure | 0.08% |
| 88 | Ball joint dust cover split | 0.08% |
| 89 | Flexible brake hose damaged | 0.07% |
| 90 | Brake relay lever fault | 0.06% |
| 91 | Power steering ram fault | 0.06% |
| 92 | Exhaust emissions above threshold (non-catalyst) | 0.05% |
| 93 | Load sensing valve fault | 0.05% |
| 94 | Towbar fault | 0.05% |
| 95 | Anti-roll bar worn or corroded | 0.04% |
| 96 | Electrical wiring fault | 0.04% |
| 97 | Tailgate damaged or insecure | 0.03% |
| 98 | Torsion bar worn or corroded | 0.03% |
| 99 | Brake fluid warning light on | 0.03% |
| 100 | Leaf spring broken or corroded | 0.03% |
| 101 | Spark ignition emissions above threshold | 0.03% |
| 102 | Steering shaft fault | 0.03% |
| 103 | Tie bar or rod worn or corroded | 0.03% |
| 104 | Driver airbag fault | 0.02% |
| 105 | Engine oil leak | 0.02% |
| 106 | Rear fog lamp not working | 0.02% |
| 107 | Suspension unit fault | 0.02% |
| 108 | Torque or reaction arm worn | 0.02% |
| 109 | Trailing arm worn or corroded | 0.02% |
| 110 | Brake back plate corroded or damaged | 0.01% |
| 111 | Engine mounting worn or broken | 0.01% |
| 112 | Hinged tailboard damaged or insecure | 0.01% |
| 113 | Reversing lamp not working | 0.01% |
| 114 | Speedometer fault | 0.01% |
| 115 | Suspension coupling worn | 0.01% |
| 116 | Suspension retaining or locking device fault | 0.01% |
| 117 | Wheel bearing worn | 0.01% |
| 118 | Additional braking device fault | <0.01% |
| 119 | Air suspension levelling valve fault | <0.01% |
| 120 | Axle corroded or damaged | <0.01% |
| 121 | Body strengthening plate corroded | <0.01% |
| 122 | Brake cable, rod, lever or linkage fault | <0.01% |
| 123 | Brake pedal linkage fault | <0.01% |
| 124 | Brake pressure or vacuum buildup insufficient | <0.01% |
| 125 | Brake servo fault | <0.01% |
| 126 | Brake slack adjuster fault | <0.01% |
| 127 | Bumper damaged or insecure | <0.01% |
| 128 | Dip switch fault | <0.01% |
| 129 | Driver door fault | <0.01% |
| 130 | Driver seat fault | <0.01% |
| 131 | Exhaust leak | <0.01% |
| 132 | Mirror or camera fault | <0.01% |
| 133 | Passenger seat fault | <0.01% |
| 134 | Vehicle floor corroded | <0.01% |
Showing all 134 reasons — scroll inside the table for the full list.
Ford Courier MOT Failures by Category
Total MOT failure occurrences for the Ford Courier, grouped by category. Same data as the failures table above — just sliced by category instead of fault title. Hover a slice for the top failures in each category.
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Frequently Asked Questions
What are the most common Ford Courier problems?
Based on analysis of 22K Ford Courier MOT tests from DVSA data, we have 39 identified common problems across 2 generations. The most frequently flagged issue is "Brake hydraulic component worn". Brakes is the most common problem category.
Which Ford Courier generation has the most problems?
The Ford Courier Mk4-based (1995-2002) (1995–2002) has the highest number of identified common problems (47). Click the generation card above for the full breakdown.
How is this data calculated?
We analyse anonymised DVSA MOT test records under the Open Government Licence. An issue is classified as a "Common Problem" when it occurs significantly more often on a specific model than the UK average, confirmed at 99% statistical confidence. Read the full methodology page for details.
Can I report a problem with my Ford Courier?
Yes — use the "Tell Us About Your Problem" form on this page. Your report helps other Ford Courier owners spot problems early. All submissions are reviewed before being added to the public database.
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