24 Common Electric Vehicle Repairs You Should Know About
Spending zero dollars at the gas station is not the only reason people buy EVs (electric vehicles). It might be the biggest incentive, but several other factors, such as emissions, acceleration, and — of course — the perceived better reliability, are part of its charm. Since EVs have fewer moving parts, we surmise they have fewer maintenance needs.
New Zealand’s DriveElectric noted that electric cars have approximately 20 moving parts, compared to the nearly 2,000 in ICE cars. That felt like a win for EV fans until Consumer Reports dropped the bomb. According to CR’s 2023 vehicle reliability survey, EVs have nearly 80% more problems and are generally less reliable than ICE cars. PHEVs are even worse, with an average of almost 150% more problems.
Hybrids are your best bet if reliability is your primary focus. CR’s study found that PHEVs have about a quarter fewer problems than gas cars. For these reasons, this article is more of a reminder than an eye-opener. We remind you that just because EVs have fewer moving parts doesn’t mean they do not require the same general maintenance as conventional automobiles. We raise 24 points that EVs can be just as headache-y as their gas-powered counterparts.
Battery Replacement
The consensus is that EV batteries last ten to twenty years. That may seem durable enough until you realize that’s not a given. Some factors can shorten their lifespan, such as a hotter climate. You’d notice the drop in range and/or the battery takes longer to charge.
In any case, battery degradation is part of the deal in EV ownership. Depending on the make and model, these things can cost anywhere from $5,000 to $20,000.
One guy in Finland was so frustrated he blew up his Tesla Model S when faced with a $22,000 bill for battery replacement. Thankfully, you’ll probably never have to pay out of pocket to replace the battery, but that’s one of the reasons many people think buying a used EV is a bad idea.
Battery Management System (BMS) Repair
You could see BMS as the EV equivalent of engine management systems in ICE vehicles. It monitors and manages the battery’s health, including the state of charge (SOC), state of health (SOH), temperature, voltage, and current, ensuring a balanced charge across all battery cells.
You want your BMS in optimal health to discharge its critical duty of disconnecting the battery from the charger in unsafe conditions, like overcharging, overheating, or deep discharge. Electric cars can have BMS issues requiring troubleshooting and repairs. Hopefully, you won’t need a full BMS replacement.
Electric Motor Repair
When they say EVs have fewer moving parts, it’s essentially a comparison between ICEs and electric motors. Electric motors are generally reliable, at least more than internal combustion engines. However, e-motors can still have issues, as should any device responsible for converting electrical energy into mechanical energy. After all, they do have parts with roles to play:
The stator, which creates a rotating magnetic field, the rotor spinning within the stator and connected to the drivetrain, the rotor’s bearing, the copper coils that generate the magnetic fields, and the cooling system that protects the motor from overheating. The motor can overheat with a fault in the cooling system, or the bearing could wear, leading to increased friction, noise, and eventual motor failure.
Inverter Repair or Replacement
The inverter delivers power to the e-motors by converting direct current (DC) from the battery into alternating current (AC) for the electric motor(s) to generate torque. The inverter is also central in the regenerative braking system, converting AC from braking back into DC for the battery.
So, a bad or faulty inverter disrupts power delivery and can even hinder propulsion entirely. The fault could be software-related, say, a bug in the inverter’s control software. Overheating can also damage the inverter, among other possible inverter issues, including connector and electrical problems. If you have to replace the thing, you could be looking at a $1,000 to $4,000 bill or more.
Charging Port Repair
The charging port is an often overlooked but highly critical EV component. Even the charging port design and/or placement can significantly affect the car ownership experience. Unlike the gas cap in ICE cars, EV charging ports are electrical in nature and more likely to develop a fault than their gas counterparts.
If you think a scarcity of charging stations is bad, wait until you have problems with the charging port. The problem could be a loose connection, internal electrical faults or wiring issues, physical damage, or bad connectors.
Onboard Charger Repair
The onboard charger is part of the charging system. It converts AC from the charging station into DC power suitable for battery charging. This, too, can need troubleshooting and repairs.
A faulty onboard charger may fail to optimally regulate the charge rate or properly communicate with the grid to start, stop, and monitor the charge. The fault can be software-related, communication malfunctions between the onboard charger and the charging grid, bad connectors, overheating, or electrical malfunctions.
Cooling System Maintenance
EVs may not require combustion engines with fossil fuels, but they need an optimally functioning cooling system just as much as electric cars. The hardworking EV batteries need to be in optimal operating temperatures, and so do the electric motors, onboard chargers, and the numerous, often complex electronics.
The cooling system has several components with a risk of failure. There’s the cooling fan, the pumps, coolants (which could leak), thermostats (which could malfunction), and radiators (risk of clogging) — all critical parts of the cooling system.
Brake System Repair
Whether electric or internal combustion, both make power, and power is nothing without control. In other words, EVs rely on a braking system to ensure the automobile can stop effectively and safely under various conditions.
The braking system has components that might wear out and/or need replacement, such as brake pads, master cylinders, rotors (discs), and calipers. Additionally, a fault in the EV’s regenerative braking system can impact the car’s overall braking efficiency.
Suspension Repairs
The suspension system is something else EVs have in common with their gas-powered counterparts. Suspension components like shocks, struts, and bushings can wear out and need repairs and/or replacement, whether the vehicle is electric, PHEV, or gas. No matter how quietly an EV goes, a bad suspension can ruin the entire ownership and driving experience.
It shares the critical responsibilities of the vehicle’s handling, comfort, and safety. Besides the struts, shocks, and bushings, the suspension system has several other components that can develop a fault, including the spring (coil, leaf, or air), tie rods, sway bars, and ball joints.
Tire Replacement
EVs let you say goodbye to the gas station, not the pavement. Even if you plan to buy a flying car, airplanes need tires for takeoff and landing, and so do some eVTOLs (electric vertical-takeoff and landing aircraft).
If anything, electric vehicle owners should be more concerned about tire health and the associated expense since EVs are typically heavier – hundreds or even thousands of pounds heavier than their gas counterparts of the same size and segment.
According to Kevin Heaslip, director of the University of Tennessee’s Center for Transportation Research, “EVs often weigh 30 percent more than comparable gas-powered vehicles because of their batteries.”
This fact is significant enough that the Canadian province of Alberta will charge EV owners $200 a year starting in 2025. The government introduced this tax in its latest budget because “EVs tend to be heavier and therefore harder on roads.” While the tax helps cover extra road wear and tears, EV owners should also budget to replace their worn tires.
Wheel Alignment
EVs, like gas cars, need wheels to support the tires. In fact, its job isn’t as simple as it sounds. The role of tire wheels, metal or alloy, includes providing structural integrity as much as it offers mounting points for tires. Where there is a wheel, there’s a need for regular alignment checks, along with adjustments if needed.
It refers to how you adjust the wheel angles parallel to each other and perpendicular to the ground. The different types of alignment include toe, camber, and caster. The caster adjusts the steering axis relative to the vertical axis, the camber adjusts the wheels relative to the vertical axis, and toe alignment adjusts the wheels relative to the car’s centerline.
You’ll notice something is off about the wheel alignment when the car starts pulling to one side or the steering wheel vibrates, shakes, and/or feels off-center. The wheels need to be set to the manufacturer’s specifications to ensure the vehicle handles optimally and the tires wear evenly.
Software Updates
These days, the convenience of patching your car’s software over the air, eliminating the hassle of taking it to the dealership, or even having to “upgrade” to a newer model makes the process feel less like a repair and more like, well, an update. In any case, electric cars more often require updates to their software systems.
Tesla was the first to offer over-the-air updates more than a decade ago, obviously inspired by the telecom sector. Not all updates are initiated and completed remotely, though. Some may require physical visits to the dealership or service center, especially when the updates apply to critical systems or hardware.
In some cases, the automaker distributes USB drives containing the software update file. Note that software updates are not always cost-free, especially when they add new features or capabilities. Consumer Reports warns that when OTA updates go south, “it can be just as dangerous as if a mechanic made a faulty repair.”
Display Screen Repair
EVs aren’t so high-tech that their infotainment systems and digital display screens are immune to failure. For example, the problem of overheating infotainment screens during fast charging forced Tesla to recall around 130,000 vehicles in 2012, affecting the Model Y, 3, S, and X.
Besides faulty infotainment CPUs, display screens can shatter or crack, pixels can die, the touchscreen can turn unresponsive or malfunction, and software glitches can cause the screen to freeze, crash, or go crazy.
Also, you may have noticed manufacturers are slowly reintroducing physical buttons and knobs. That’s because many EV owners complain of “screen fatigue” due to the excessive reliance on touchscreens and digital interfaces to operate the vehicle.
Sensor Calibration
These days, it’s almost unthinkable for a new car to launch without some ADAS (advanced driver-assistance system) or self-driving capabilities. Drivers can hardly overlook their absence in ICE models, let alone electric vehicles. The various ADAS and safety systems typically work with sensors, and sensors need regular calibration to stay accurate.
Namely, radar sensors (powering ADAS features like adaptive cruise control, collision avoidance, and lane-keeping assist), camera sensors (powering features like lane departure warning, parking assist, and traffic sign recognition), speed and positioning sensors (providing speed and position measurement data for automatic braking and traction control features), ultrasonic sensors, and LIDAR sensors (for high-resolution mapping and object detection).
An accident, software update, suspension or wheel alignment work, or even normal wear and tear can call for sensor calibration.
HVAC System Repair
EVs need cooling and cabin temperature control, just like combustion cars. The heating, ventilation, and air conditioning (HVAC) systems come with many components that can need repairs at some point.
There’s the compressor with its AC clutch, heater core, condenser, blower motor, evaporator, orifice tube (also called expansion valve), and HVAC control module. All these components play crucial roles in the all-encompassing HVAC system, ultimately resulting in something akin to a nuclear effect should one or more components have issues.
Drivetrain Repair
If you think EVs are worry-free machines you buy and drive forever, with where you can find the closest charging station as your only concern, the coming rude shock is unintentional.
We regret to jolt you back to the reality of drivetrains – drivetrains with components that need repairs now and then, such as the driveshafts (if applicable), electric motors, power electronics controller, transmission, DC converter, thermal management system, battery pack, onboard charger, and axles.
A problem in the drivetrain impedes power transmission from the motors to the wheels.
Electrical System Diagnostics
There have been discussions over which is worse: Electrical or mechanical problems? Experience has taught many car owners that mechanical issues are the better of the two devils.
As seen on an online forum, “Electrical faults are more frustrating than mechanic faults in cars… That’s why I can buy a vehicle with a knocked engine/gear but wouldn’t come within 10 kilometers of a flooded vehicle. The worst case with a mechanical fault is to replace the entire component, be it gear, engine, or whatever. But some electrical faults are village people [witches] on steroids…. Tears unlimited….”
Unfortunately, troubleshooting electrical issues, such as faulty wiring or connectors, is common with EVs.
Charging Cable Replacement
This one is peculiar to electric cars. Owners often have to replace damaged charging cables to ensure a safe and efficient transfer of electrical energy from the charging grid to the EV battery. In most cases, these cables are handled almost daily, making them prone to frays, kinks, or cuts.
The connectors can also become loose or corroded over time. There’s a high likelihood that the charging cable is to blame for charging issues unrelated to the charging station or the car itself. These things can set you back anywhere from $200 to $600.
Regenerative Braking System Repair
This one is also peculiar to electric and electrified vehicles, including PHEVs and mild hybrids. It’s a key feature designed to recover what would’ve been lost kinetic energy during braking, storing the recovered energy in the battery pack for future use.
For instance, what is the Toyota Prius without its regenerative braking system? The electric motor, battery pack, brake pads, inverter, and brake cable modules contribute to the regenerative system. A fault in one affects the system, setting you back an excess of $1,000 if the motor or battery is affected.
Firmware Recalibration
EVs need their firmware recalibrated from time to time to ensure optimal performance. They may be low-level software, but the vehicle’s hardware, such as the e-motor(s), sensors, and battery system, rely on the firmware to communicate with operating systems.
In short, firmware is like the squire embedded in the knight (hardware components such as sensors) to manage their operations.
So, they’re everywhere – the infotainment system, engine control unit, battery management system, safety systems, transmission control module, etc. Electric vehicles need their firmware recalibrated to fix bugs, meet new regulations, optimize performance, and ensure compatibility.
Lighting System Repair
Electric cars develop faults in their lighting systems as gas-powered cars. If it isn’t problems with the headlights, then the taillights, turn signals, fog lights, or interior lights. They all can malfunction and need repairs.
A faulty lighting system is serious enough that Tesla issued a recall for 2.2 million cars in the US to correct the warning lights’ font sizes. Apparently, the font affects the ease of reading and interpreting the alerts. Kia also recalled the EV6 due to dash light display-related issues.
Sealing and Weatherproofing
Electric vehicles aren’t immune to degrading doors and window weather seals. It’s common for seals to dry out, crack, or become brittle with time. Often, car owners fail to notice until water starts leaking somewhere or the wind noise becomes unbearable.
Water leakage may go unnoticed, especially in hidden areas like the trunk, hood, windshield, and rear windows, until mold, mildew, or rust gives it away. You can repair minor cracks or gaps in seals with sealants. You can also use them to enhance the weatherproofing of existing seals.
Windshield Wiper Replacement
Yeah, don’t forget the wipers and washer systems. They, too, need regular maintenance, whether or not the car is electric, PHEV, hybrid, fuel cell, or gas. Replacing wipers is simple enough, but removing the smears, smudges, and streaks on your windshields due to worn or damaged wiper blades isn’t as simple.
The smears let you know it’s time to replace the wipers, and so do the chattering or squeaking noises while they clean, the skipping due to improper contact with the glass, the visible split rubber, and inefficient cleaning. The consensus is to replace the wiper every six to twelve months, depending on the environment and how you use the thing.
Interior Upholstery Repair
Electric vehicles, including supercars, SUVs, trucks, sports cars, or compact cars, can benefit from high-quality cabin materials. However, none can last forever because tears and rips happen, as do stains and spills, burns and fades, sagging headliners, loose or torn seams, worn padding, and discoloration.
High-quality leather can last many years if properly maintained, the same as vinyl, wood, and synthetic materials like Alcantara. Whether made of high- or low-quality materials, car seats, and interior materials eventually wear out and need repairs or replacement.
