Most reliable LCVs

When you run a van for business, every day it’s off the road costs you more than just the repair bill. It means missed deliveries, delayed jobs, and disappointed customers. And according to our latest claims data here at Warranty Solutions Group (WSG), those costs are quietly stacking up for thousands of van operators across the UK.
We’ve analysed over 1,000 light commercial vehicle (LCV) warranty claims made between July 2024 and June 2025 – and the results are eye-opening.

Some repairs are so expensive they can eat into your profits in a single hit.
The priciest claim of the year went to a Mercedes Sprinter 316 CDI with an engine-related failure costing over £6,000. Not far behind, a Citroën Berlingo racked up nearly £5,000 for a major engine fault.
The Ford Transit appeared three times in the top 10 most expensive claims – from timing belt failures to turbocharger problems and even a full engine rebuild. And the Vauxhall Vivaro also made repeat appearances, mainly due to costly engine and diesel particulate filter (DPF) repairs.
Across the board, the top 10 highest-value claims ranged from £2,500 to £6,000+, with many hitting the upper limit of warranty policy payouts. That means any shortfall is coming straight out of an operator’s pocket.

While those headline-grabbing repair bills are painful, the most common faults can be just as damaging over time – especially for fleets.

Our data shows the top three most common claims were:

• Alternators – 5.35% of claims, average cost £506.78
• NOx sensors – 4.51% of claims
• Diesel injectors – 3.67% of claims

Other repeat offenders included dual mass flywheels (£943.48), turbochargers (£872.89), and EGR coolers (£850.98). But the part with the highest average repair cost? The DPF, at £1,303.75 per claim.

Individually, these repairs may look manageable – but when the same fault hits multiple vans in quick succession, downtime and costs can spiral.

Modern vans are more complex than ever – and that’s before we factor in stricter emissions regulations.

Parts like NOx sensors, EGR valves, AdBlue injectors, and DPFs are vital for meeting environmental standards, but when they fail, they’re costly to replace. And because many of these components don’t show obvious signs of wear until they fail completely, repairs often come as an unpleasant surprise.

Switching to electric vans can reduce some traditional repair risks, but it introduces new ones. EV claims often involve battery systems, inverters, or thermal management components – all of which require specialist knowledge and come with higher labour rates.

While EVs have fewer moving parts, when they do fail, costs can be as high (or higher) than for diesel or petrol vans. That’s why more operators are considering extended EV-specific warranty cover before making the switch.

Our data shows that repair costs are no longer just a nuisance – they’re a strategic consideration for every van operator. Here’s how you can stay ahead:

1. Let repair data guide your buying decisions – Choose models with fewer high-cost failures in our claims history.
2. Be proactive with maintenance – Many high-cost parts, like DPFs and NOx sensors, degrade over time. Regular servicing can catch problems earlier.
3. Review your warranty cover – If you’re running vans with known recurring faults, make sure your policy limits match the potential costs.
4. Plan for the EV shift – If you’re adding electric vans, factor in new fault patterns and potential warranty needs.

Bottom line: A single major repair can disrupt your business, but knowing which parts fail most – and when – can help you plan, budget, and protect your fleet.

At WSG, we use live claims data to help you make smarter decisions about vehicle selection, maintenance, and warranty cover. Because when your vans stay on the road, your business stays on track.