The EV Repair Myth: Batteries Aren’t the Biggest Problem for Used Electric Vehicles

But new warranty claims data from Warranty Solutions Group (WSG) suggests that this narrative is increasingly out of date. As more EVs enter the used market and early warranties begin to expire, the real cost of ownership is proving to be something very different.

For UK dealers, especially those stocking used EVs, the findings are a timely reminder that the biggest risks aren’t always where customers expect them to be.

One of the most striking findings from WSG’s analysis is that battery faults account for just 2.09% of all single-fault EV warranty claims.

Despite being the most talked-about component in electric vehicles, batteries are not currently the primary driver of warranty activity or repair exposure.

Instead, the data shows that issues are far more commonly linked to charging systems, electrical hardware and everyday vehicle components that are increasingly familiar to technicians working across the wider vehicle parc.

In other words, EV reliability challenges are becoming less “EV-specific” and more aligned with general vehicle complexity.

• Central locking faults (4.29% of claims – the most common EV issue)
• Charge flap actuator failures (3.57%)
• Lower arm suspension repairs (2.86%)
• Parking distance sensor (PDC) faults (2.86%)

The pattern is clear: as EVs age and accumulate mileage, their fault profile begins to resemble traditional vehicles—just with added electrical complexity layered on top.

• Average labour rate: £92.04 per hour
• Labour share of total repair bill: 29.9%
• Average labour time per claim: 2.07 hours
• Average labour cost per claim: £207.08

While EVs typically require less routine servicing than internal combustion engine vehicles, they often demand more specialist diagnostics and high-voltage expertise when things do go wrong.

For dealers, this is an important operational consideration. Even when part costs are manageable, labour and diagnostic time can quickly escalate total repair exposure.

Perhaps the most commercially relevant insight for dealers is just how wide the reliability gap has become between different EV models.

At the other end of the spectrum, however, the gap is significant:

• Tesla Model S – 34.78%
• Mercedes-Benz EQV – 33.33%
• Tesla Model X – 29.17%

To put that into context, the Tesla Model S recorded a claim rate more than 23 times higher than the Renault Zoe.

For dealers, this reinforces a growing reality: EVs cannot be treated as a single homogeneous category when it comes to risk, stocking strategy or warranty planning.

While many EV faults are relatively minor, the data also highlights the potential for high-cost outliers when major systems are involved.

The largest EV warranty claim recorded by WSG over the last 12 months reached £4,801.24, relating to a Jaguar i-Pace battery system repair.

Across the dataset, the most expensive repairs were typically associated with premium EV models, with brands including Jaguar, Porsche, Tesla, Mercedes-Benz and Ford featuring in the highest-cost claims.

This reinforces an important point for dealers: low claim frequency does not always equal low financial exposure.

Some vehicles may be relatively reliable day-to-day, but when failures occur, the cost can be substantial.

“One of the biggest misconceptions surrounding electric vehicles is that batteries are the primary source of faults. The reality is very different.”

“Our claims data shows that batteries account for a relatively small proportion of overall repairs. What we’re increasingly seeing are issues involving charging systems, electrical components, sensors and vehicle electronics.”

“The EV conversation has changed dramatically. Five years ago consumers were asking how far an EV could travel. Today they’re asking what happens when it breaks, how much it will cost to repair and whether they can buy with confidence in the used market.”

For dealers, that shift is already visible in customer behaviour—particularly around warranty expectations and questions about long-term running costs.

As more vehicles come out of manufacturer warranty periods and enter independent retail channels, buyers are becoming more focused on:

• Repair costs
• Reliability by model
• Warranty protection
• Real-world ownership experience

Range anxiety is no longer the dominant concern it once was. Instead, financial predictability and repair risk are moving to the forefront.

This is where warranty protection is becoming increasingly relevant—not just as a value-add at point of sale, but as a core part of customer confidence in used EVs.

As complexity increases, so does the importance of managing expectations around ownership costs.