Warrantywise Reveals Common EV Faults & Repairs

For those working in motor claims it’s good to know which faults and problems are most likely to affect EVs;

As the used electric vehicle market matures and consumer confidence in electrification grows, increasing numbers of buyers are choosing pre-owned EVs through franchised and independent dealer networks. To help retailers better understand this changing landscape, Warrantywise – a trusted provider of extended used car warranties for more than 25 years – has analysed its repair request data to reveal new insights into used EV reliability, ownership patterns and aftersales considerations across the second-hand market.

With more used car buyers considering electric vehicles, car dealers have a clear opportunity to build confidence on the forecourt. Understanding the repair issues most commonly seen in real-world EV ownership can help dealers appraise stock more effectively, answer customer questions with greater certainty, and support buyers with suitable extended EV warranty options.

For dealers investing in used EV stock, understanding real-world repair trends is becoming increasingly important. While Warrantywise’s repair request data shows that EV battery-related repairs are comparatively uncommon, several of the most common repair areas still carry meaningful average repair request costs, including the on-board charger and suspension components. This gives retailers a more informed way to discuss used EV ownership with customers, while demonstrating how an EV-specific extended warranty can help them budget for unexpected repair bills and build confidence at the point of sale.

These are the five most common repair requests for used electric vehicles.

Top 5 used EV repair requests*

The latest used EV Reliability Warrantywise dataset proves that reliability isn’t just about EV technology. Instead, electrical system faults, including sensors and central locking mechanisms, topped the repair request list, with average repair request costs of £809.59** and £899.44 respectively. However, individual repair requests reached as much as £3,270.00 for sensor-related issues and £4,056.82 for central locking repairs. Repairs to the auxiliary (12V) battery also featured in the top five, with an average repair request cost of £532.94.

Meanwhile, suspension-related components such as wishbones recorded an average repair request cost of £1,229.64, with the most expensive repair request reaching £4,118.65. The only EV-specific repair category in the top five was the on-board charger, highlighting the importance of charging systems in real-world EV ownership. While the average repair request cost was £2,158.75, the highest repair request reached £10,454.98, showing that although uncommon, some EV-specific repairs can be particularly costly.

Warrantywise, a trusted source of EV reliability insight, also uncovered data on EV battery repair requests, which, though infrequent, are naturally of concern. When an EV battery issue does occur, repair request costs are on average £6,435.38.

With this context, it’s important to remember that for retailers and dealer groups, EV repair request costs remain an important consideration when preparing stock and supporting customers through the sales process. Although average EV repair request values rose by 10.7% from 2024 to 2025, wider market conditions – including inflationary pressures, parts supply and workshop labour rates – remain important contributing factors. While many repairs are relatively modest in cost, the variation between average and highest repair request values highlights the potential for unexpected and expensive repairs. For dealers, this reinforces the importance of understanding real-world EV repair trends and the role an EV-specific extended warranty can play in helping buyers budget with greater confidence when purchasing a used electric vehicle.

Meanwhile, for drivers seeking greater certainty when making the important decision to buy a second-hand EV, and keen to manage unexpected repair costs, a warranty can be an important part of the sales package. For used car dealers, offering a suitable extended EV warranty can reduce buyer objections around used EVs and protect gross margin from post-sale repair concerns. Knowing the most common repairs can also give sales teams a clearer way to explain EV ownership risk more accurately.

For more information on Warrantywise’s EV-specific warranties, please visit  https://www.warrantywise.co.uk/ev-electric-car-warranty/