2010 Ford Fusion 1.6L Petrol · FD59 NOU

A clear mechanical theme runs through the recorded MOT history of this 2010 Ford Fusion: chronic fluid leaks from the gearbox combined with recurring corrosion on the brake pipework and progressive deterioration of suspension joint gaiters. Across the four most recent tests, a gearbox oil leak has been recorded every year since 2023, and brake pipe corrosion has appeared on both nearside and offside front lines in consecutive tests, culminating in a Major failure for excessively corroded offside rear brake pipe in February 2022. The pattern is compounded by repeated lower suspension arm ball joint dust cover failures, slight play in the nearside front lower arm in 2023, and an upper anti-roll bar ball joint dust cover noted as severely deteriorated in the most recent test on 31 January 2026. That latest test was a pass, but it carried two Minor defects and three advisories, and the cumulative picture is one of steady, ongoing wear rather than resolved repair. With 129,428 miles recorded over approximately sixteen years, the vehicle is accumulating roughly 8,000 miles annually, which sits close to the average for its age. There are no extended gaps in the testing record and no sudden mileage jumps, indicating continuous use rather than long periods of standing. This continuous usage profile means the mechanical components have been worked consistently, which generally keeps seals supple and prevents the kind of corrosion that affects laid-up vehicles, but it also explains why consumables and underbody components are showing wear typical of a high-mileage car. The gearbox oil leak, in particular, has been flagged as not excessive on every occasion, suggesting a slow seep that warrants monitoring rather than immediate panic. For a prospective test drive, particular attention should be paid to the suspension components flagged in the advisories. With the nearside front lower arm ball joint recorded as having slight play in 2023 and the offside front upper anti-roll bar ball joint dust cover now severely deteriorated, listen for clonking or knocking noises from the front end when traversing speed bumps or potholes, and feel for any vagueness or looseness through the steering wheel on uneven surfaces. The brake pedal was noted as wearing smooth in the most recent test, so check for consistent pedal travel without excessive play or any sponginess that might indicate brake fluid renewal is overdue. On the road, the vehicle should stop squarely without pulling to either side, particularly given the historical brake pipe corrosion, and a firm pedal feel is essential given the age of the underbody pipework. The persistent gearbox oil leak, although not flagged as severe, should be inspected physically before purchase. Look underneath the vehicle for any fresh drips on the driveway or ground, check the gearbox casing for wetness, and verify the oil level on the dipstick if accessible. The brake pipe corrosion history, spanning four consecutive tests, warrants a thorough underbody examination with the vehicle raised if possible, paying close attention to the rear offside line where the Major failure occurred, the flexi hoses, and any unions near the subframe mounting points. Replacement of corroded brake sections is typically straightforward, but the cost escalates if corrosion has spread to multiple lines or rear axle pipework. Finally, confirm that the rear fog lamp noted as inoperative on the 2022 and early 2023 tests has been rectified and verify operation of all registration plate lamps, given the most recent Minor defect for an inoperative nearside rear plate lamp.