One of the best aspects of electric vehicles (EVs) is their low maintenance costs compared to traditional cars. Unfortunately, when things go wrong, not every repair is as cheap as you might first think. EVs use a lot of complex parts that can require specialized mechanics. These limited repair options mean that sometimes, EV fixes can be surprisingly costly.
Here are 15 EV repairs that might leave you with a bill that’s a lot larger than you expected.
Battery Replacement
Depending on the model, a new car battery can cost anywhere from $5,000 to over $20,000. This repair is like replacing your entire engine because, like car engines, batteries degrade over time. This happens especially if exposed to extreme temperatures or frequent fast charging.
However, even small scratches can lead to complete replacements being needed. While warranties often cover battery replacements for a while, once those expire, you’re on your own.
Inverter Repairs
When this component goes wrong, the cost of repair or replacement can be really high because only specialized technicians can fix it. Issues with the inverter can affect the overall performance of your car, leading to reduced range or even a complete breakdown. Neither of these problems is good for your bank account. Finding a mechanic with the right expertise might take time, adding inconvenience to the already high repair bill.
Charging Port Malfunctions
Whilst this fault might not seem too serious, it will cause you a lot of problems if you ever need to use your car. Charging ports experience a lot of wear and tear from frequent use and environmental factors like moisture or dirt.
Repairing or replacing these ports can cost hundreds of dollars, especially if additional components like the onboard charger are affected. People don’t usually think about being careful with their car charging ports, but they do with their phones. Either way, you wouldn’t have to pay to repair the fuel part in a conventional car.
Motor Repairs
Problems with the motor in your EV might come from overheating, electrical faults, or manufacturing defects. Unlike internal combustion engines, electric motors are often sealed shut, making these kinds of repairs challenging and expensive. Replacing an entire motor can cost thousands of dollars, and the availability of the parts you need can make the process even more complicated.
High-Voltage Cable Replacement
High-voltage cables are heavily insulated and designed to handle significant loads, but repairing or replacing them requires specialized tools and expertise. If you’re unlucky, costs can run into the thousands, depending on how bad the damage is and the model of your vehicle.
The damage often occurs due to accidents or stupid handling during repairs, so protecting these cables with regular inspections can help stop some huge repair bills.
Software Updates and Diagnostics
Unlike traditional vehicles, EVs rely heavily on software for their operation. This means when glitches or errors occur, the diagnostics and updates to fix them can be surprisingly costly. Sometimes, it’s not as simple as replacing a broken part like in a normal car; the problems can be much harder to locate and solve. Some updates will be free, but major software issues often require a visit to the dealership.
Thermal Management System Repairs
The thermal management system in EVs keeps battery and motor temperatures normal, ensuring optimal performance. When this system fails, it can cause overheating or reduced efficiency in your car. Reduced efficiency will impact how much it costs to keep charging, but overheating parts will cost much more.
Components like pumps, radiators, or control modules will make thermal management system repairs cost a lot more than you might first think.
Onboard Charger Issues
If your onboard charger experiences problems, charging will become impossible until it’s repaired or replaced. The cost of replacing an onboard charger can range from $1,000 to a ridiculous $3,000, depending on the model. Onboard chargers are prone to wear over time, so this will become an issue whether you like it or not.
These problems can happen sooner than expected if your EV is exposed to power surges or incompatible charging equipment.
Suspension Repairs
Electric vehicles often have much more complex suspension systems than normal cars because they need to handle the added weight of their battery packs. Issues like damaged control arms or broken shocks can quickly add up, leading to costly repairs, especially if specialized parts are required. Some EVs even feature air suspension systems, which are even more expensive to repair or replace.
Touchscreen and Infotainment System Replacements
Modern EVs often have really advanced touchscreens and infotainment systems. When these systems fail, replacement costs can set you back thousands of dollars. The complexity of these units means that repairs are rarely an option, so owners must replace the entire system.
Avoiding harsh cleaning products and ensuring software is updated can help prevent unnecessary replacements, but if you encounter problems, you won’t be happy.
Wheel Bearing Failures
Because of how heavy the batteries are in EVs, wheel bearings encounter a lot of additional stress that you wouldn’t usually find in a normal car. This added stress can result in more frequent failures than you would like. Replacing wheel bearings might not seem like something that would cost a lot, but in EVs, the process can require lots of labor and cost more due to complex components.
Brake System Repairs
Regenerative braking systems in EVs reduce wear on traditional brake components, but when repairs are needed, they can cost more than expected. Since they’re more complicated than normal braking systems, parts like calipers or sensors are much more expensive to replace. Issues with the electronic brake control system can also add to the bill.
The only way to mitigate these problems is to maintain and inspect traditional components regularly, which helps avoid larger repair costs.
Body and Structural Repairs
The lightweight materials used in EVs, such as aluminum or composites, make them efficient but also expensive to repair if you ever have an accident. Fixing dents, cracks, or frame damage often requires the same expensive specialized tools and expertise you might have come to expect after reading this article.
Additionally, EVs may have sensors or wiring integrated into body panels, further complicating repairs. There’s a lot that can go wrong. Accidents are common, so don’t be surprised when your repair bills are more than your old gas-fueled car.
Charger Compatibility Fixes
These issues come from compatibility errors between the vehicle and certain chargers, which can result in unexpected repair costs. These fixes often involve recalibrating software or replacing connectors, which can be super expensive. Make sure you use certified chargers and follow manufacturer recommendations if you want to help avoid these compatibility problems.
This won’t always be possible because charging stations are still fairly limited in the world, so maintenance costs might be an inevitable issue because of incompatible chargers.
Electronic Control Unit (ECU) Failures
The ECU is a vital component in EVs, managing everything from battery performance to motor output. When the ECU fails, it can lead to major disruptions and costly repairs. Replacing or reprogramming an ECU requires specialized equipment and expertise, making it a significant expense.
Regular software updates and prompt diagnostics help prevent ECU failures, but if you encounter problems you will be shocked by how much they cost to fix.