Hidden faults and simple fixes drive MOT failures across UK fleets

Suspension defects and minor maintenance issues are emerging as the leading causes of MOT failures, highlighting gaps in routine checks that can increase fleet downtime and cost.

New data from HiQ Tyres and Autocare shows suspension-related faults are now the most common issue, often developing gradually without obvious warning but affecting vehicle stability and braking performance.

Key MOT failure drivers:

  • Suspension faults - 38.1% (worn components, broken springs, leaking shock absorbers)
  • Lighting and electrical - 37.4% (bulbs, headlights, wiring issues)
  • Tyres and brakes - 25% each (tread wear, structural damage, braking performance)
  • Steering - nearly 25%

Road conditions are a contributing factor, with potholes accelerating wear on suspension and steering components.

Alongside mechanical issues, DVSA data highlights a separate pattern of preventable failures linked to basic maintenance.

Low-cost faults still causing failures:

  • 216,388 MOT failures in 2025 due to faulty washer jets
  • 592 failures per day
  • 29,405 failures from incorrect washer jet alignment

Awareness remains low, with 26% of drivers unaware washer jets can fail an MOT and 69% not confident replacing them.

Fleets looking to reduce failure rates can combine regular SMR inspections with simple driver-led checks before testing. Platforms such as FleetCheck bring compliance, inspections and vehicle data into one system, helping identify defects earlier. Telematics providers including Webfleet can also flag emerging faults and monitor driver behaviour, reducing wear on key components.

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