🚗 Body, chassis, structure MOT Failures
Body and structure failures cover corrosion, damage, or deterioration to load-bearing structural members, chassis rails, sills, subframes, and mounting points that compromise vehicle safety.
Data from official DVSA MOT testing records
✅ Best 20 — Lowest Body, chassis, structure Failure Rate
These models have the lowest body, chassis, structure failure rate in MOT testing. Great choices if you want to avoid body, chassis, structure problems.
| # | Make | Model | Failure Rate | Total Tests |
|---|---|---|---|---|
| 1 | BMW | 218i M | 0% | 8,608 |
| 2 | Fiat | Swift | 0% | 27,557 |
| 3 | Nissan | Nv400 | 0% | 35,913 |
| 4 | Tesla | Model 3 Performance Awd | 0% | 27,886 |
| 5 | MG | Hs | 0% | 6,847 |
| 6 | Vauxhall | Astra Sportive | 0% | 11,496 |
| 7 | Mercedes-Benz | A 250 Amg Line E Auto | 0% | 9,065 |
| 8 | BMW | X6 (e71) | 0% | 18,987 |
| 9 | Tesla | Model 3 Long Range Awd | 0% | 66,623 |
| 10 | Skoda | Karoq | 0% | 132,958 |
| 11 | Mazda | CX-5 | 0% | 326,565 |
| 12 | Mercedes | Ml 320 Cdi Sport A | 0% | 8,863 |
| 13 | Ferrari | 488 | 0% | 8,529 |
| 14 | Ford | Fiesta Zetec Auto | 0% | 5,260 |
| 15 | Peugeot | Bailey | 0% | 5,061 |
| 16 | Ford | Fiesta Stline X Edition T Mhev | 0% | 6,949 |
| 17 | Mini | Cooper S Electric Level 3 | 0% | 7,952 |
| 18 | Lotus | Exige | 0% | 14,941 |
| 19 | BMW | X3 Xdrive20d M Sport Auto | 0% | 6,475 |
| 20 | Ford | Focus St-line X Edition Mhev | 0% | 6,278 |
❌ Worst 20 — Highest Body, chassis, structure Failure Rate
These models have the highest body, chassis, structure failure rate. Consider extra inspection before buying.
| # | Make | Model | Failure Rate | Total Tests |
|---|---|---|---|---|
| 1 | Ford | Transit 190 Lwb | 32.5% | 11,469 |
| 2 | Ford | Escort Lx | 26.1% | 7,253 |
| 3 | Carbodies | Taxi/hire Car | 22.6% | 11,564 |
| 4 | London Taxis Int | Tx1 Bronze | 21% | 39,795 |
| 5 | Daihatsu | Fieldman | 18.7% | 16,407 |
| 6 | Nissan | D21 | 18.5% | 9,712 |
| 7 | Ford | Fiesta Courier | 18.1% | 36,129 |
| 8 | Ldv | Cub | 17.7% | 20,873 |
| 9 | Nissan | Cabstar Lwb Diesel | 17.5% | 5,173 |
| 10 | Nissan | Terrano Ii | 17.2% | 128,304 |
| 11 | Nissan | Vanette | 17.1% | 73,633 |
| 12 | Daihatsu | Fourtrak | 17% | 80,881 |
| 13 | Suzuki | Sj413 | 16.7% | 10,808 |
| 14 | Land Rover | 110 Defender Turbo Dies | 16.6% | 6,654 |
| 15 | Land Rover | 90 4c Sw Dt Diesel | 16.5% | 5,423 |
| 16 | Volkswagen | Delivery Van | 16.3% | 11,143 |
| 17 | Suzuki | Sj410 | 15.9% | 6,090 |
| 18 | London Taxis Int | Tx1 Silver | 15.5% | 26,857 |
| 19 | Mazda | B-series | 15.4% | 14,371 |
| 20 | Daihatsu | Sportrak | 15.2% | 22,681 |
💡 How to Avoid Body, chassis, structure Failures
- ✓ Inspect sills, wheel arches, and chassis rails for rust — especially on cars over 10 years old or those used in coastal areas.
- ✓ Apply anti-corrosion wax or underseal to vulnerable areas as preventive maintenance.
- ✓ Address stone chips and paint damage quickly to prevent rust from taking hold on structural panels.
Frequently Asked Questions
What body corrosion causes an MOT failure?
Corrosion that has weakened structural or load-bearing components fails the MOT. This includes corroded sills, chassis legs, subframe mounting points, seat belt anchor points, and suspension mounting points. Surface rust alone doesn't fail.
Can body corrosion be repaired to pass the MOT?
Yes — structural corrosion can be repaired by welding in new metal. Repairs must restore the original strength of the component. Costs vary from £100-£500+ depending on the extent of corrosion and accessibility.
Which cars rust the most?
Corrosion rates vary significantly by model, manufacturing quality, and materials used. Check the rankings on this page to see which models have the highest and lowest body corrosion failure rates.
Based on DVSA anonymised MOT test data (2005–2024). Crown copyright, Open Government Licence v3.0.