Ensuring your fleet is compliant is important for keeping commercial vehicles and buses on the road and out of the workshop. And with more than 10% of commercial vehicles failing their initial MOT test according to the latest figures from the Driver Vehicle Standards Agency, operators risk avoidable downtime and added cost if they don’t keep their vehicles compliant.
Government data shows that:
- HGVs fail their MOTs 10.22% of the time
- Trailers fail at a rate of 8.32%
- Public Service Vehicles (PSVs) fail 9.21% of the time
Many of these failures are preventable through proactive maintenance and defect management. By automating and tracking these processes through a fleet management software system like Jaama’s Key2 platform, operators can ensure defects are identified and fixed early, inspections are never missed, and repair records are fully traceable.
Here are the top five reasons for MOT failures across the three key commercial vehicle categories, as reported by the Driver and Vehicle Standards Agency (DVSA).
- Brake system issues
HGV: 6.24% of all tests
Trailer: 4.63% (plus 2.86% for service brake performance and 1.95% for parking brake)
PSV: 2.21%
Brake system failures are consistently the most common cause across all vehicle types. This includes worn pads or discs, poorly performing service brakes, and ineffective parking brakes, often due to a lack of regular inspections or poor record keeping.
With Jaama’s Maintenance Exchange, fleet operators and service providers can easily track and manage brake inspections, share digital job sheets, store paperwork and highlight problems as a code red to fleet managers and in house workshops.
- Lighting defects
HGV: 2.52%
Trailer: 1.55%
PSV: 2.05%
Lighting issues such as faulty indicators, brake lights, or misaligned headlights, are another major failure category. While they’re usually quick fixes, insufficient pre-MOT checks or responding to drivers’ daily inspection findings can result in an MOT failure.
Jaama’s Key2 system ensures all driver-reported defects (including lighting) are logged, actioned, and traceable via the integrated Vehicle Inspection App, providing a clear audit trail and real-time visibility of outstanding defects.
- Suspension damage
HGV: 3.09%
Trailer: 0.74%
PSV: 0.97%
Suspension components like shock absorbers and leaf springs wear over time, but they’re often missed unless proactively inspected. A single broken spring or worn bushing can lead to a fail.
Automated service scheduling via Key2 ensures suspension systems are inspected at intervals recommended by the manufacturer and allows for preventative maintenance planning to help solve problems before they occur. That means worn suspension parts can be addressed before they put a vehicle out of action.
- Tyre condition
HGV: 3.59%
Trailer: 0.5%
Bald spots, sidewall damage or underinflated tyres can all trigger an MOT failure. For HGVs, tyre condition is one of the most overlooked issues, and tyre wear on the inside side walls of tractor units or trailers can be particularly hard to spot without a proper inspection process in place by drivers or workshops.
With Jaama’s Vehicle Inspection App, tyre checks are logged in real time by drivers, and tyre condition and replacement records are stored and tracked within Key2. This ensures early warnings are flagged and addressed before an MOT test takes place.
- Obstructed view of the road / bodywork defects
HGV: 2.76% (Visibility)
PSV: 2.27% (Interior body, steps, and exits)
For HGVs, a cracked windscreen or defective mirror could result in a fail. In PSVs, many fail to meet high enough standards of structural integrity, while also falling short in safety features such as entrances, exits, platforms, and interiors, which are essential for safe operation.
By centralising all vehicle defect reports and documentation, Jaama’s platform ensures nothing gets overlooked. Whether it’s visibility, safety gear, or structural integrity, all critical items are checked, recorded, and maintained.
Stay MOT-ready with Jaama
With thousands of MOT tests resulting in failures every year, the best way to reduce risk is through consistent, connected vehicle maintenance management.
Jaama’s Key2 Maintenance Exchange platform includes a dedicated MOT module that helps fleets track expiry dates, schedule tests in advance, and maintain full compliance records. This help fleets digitise compliance and streamline communications with service providers, reducing downtime and avoiding costly failures.