A new analysis challenges the belief that battery failures are the main financial risk for electric car owners. Most costly repairs actually involve everyday components, not the high-voltage battery pack.
For many drivers considering an electric car—especially on the used market—the prospect of a costly battery replacement looms large. Yet new data from the UK-based warranty provider Warrantywise suggests this fear may be misplaced. According to their latest study, the most frequent and expensive repairs in electric vehicles (EVs) rarely involve the main traction battery at all.
The report, based on thousands of repair claims for used EVs, paints a clear picture: the majority of breakdowns are linked to components shared with conventional cars. Electrical sensors, central locking systems, and suspension parts top the list of trouble spots, while high-voltage battery failures are far less common than many expect.
Unexpected Repair Leaders
Warrantywise found that electrical system sensors are the most common culprit, with an average repair bill of £809.59 (about €940). In some cases, costs soared to £3,270 (€3,800). Central locking malfunctions, often dismissed as minor, actually cost more on average—£899.44 (€1,045)—with the priciest fix reaching £4,056.82 (€4,710).
The first EV-specific part to appear in the rankings is the onboard charger, responsible for managing battery charging from the grid. Repairs here average £2,158.75 (€2,510), but the most expensive case hit £10,454.98 (€12,150). Suspension arms are another frequent headache, with average costs of £1,229.64 (€1,430) and a maximum of £4,118.65 (€4,780).
Even the humble 12-volt auxiliary battery—a part found in both electric and combustion cars—makes the list. Replacing it is relatively affordable, averaging £532.94 (€620), though the highest recorded bill was £986.15 (€1,145).
The Battery Paradox
So what about the main traction battery? The study confirms it remains the single most expensive repair when it does fail, with an average cost of £6,435.38 (€7,480). However, such failures are rare. Most EVs never experience a major battery issue during their typical lifespan, and the vast majority of workshop visits are for more familiar, less dramatic faults.
Antony Diggins, CEO of Warrantywise, notes a persistent gap between perception and reality: “For many used EV buyers, the battery is still the biggest worry. But our repair data shows a much more balanced picture. The most frequent issues are with everyday components—sensors, central locking, suspension, and the auxiliary battery—not the main EV battery.”
He adds that these findings could help dealers address common misconceptions: “It’s an important message for the industry. Dealers can explain what EV ownership really looks like, correcting myths without hiding the fact that some repairs can still be significant. With four-figure average costs for parts like the onboard charger or suspension, a dedicated EV warranty can play a key role in building buyer confidence.”
Rising Costs and Broader Context
The report also highlights a 10.7% increase in average EV repair costs between 2024 and 2025. Warrantywise attributes this not only to the complexity of EV technology, but also to inflation, pricier spare parts, and higher labor rates in workshops.
While the focus is often on battery longevity, the data suggests that most EV owners will spend more time and money maintaining the same types of parts that fail in any modern car. This trend echoes broader developments in the electric vehicle market, where advances in battery durability are shifting attention to other aspects of ownership. For example, the push for more robust and high-performance EVs—such as the new generation of plug-in hybrids highlighted in recent industry launches—is changing both expectations and realities for drivers and manufacturers alike.
In summary, while battery replacements remain a costly outlier, the real story for most electric car owners is the persistence of everyday mechanical and electrical issues. As the EV market matures, understanding these patterns will be crucial for buyers, sellers, and service providers navigating the next phase of automotive change.
