EV Repair Costs & Complexity Are on the Rise

August 14, 2025

1. EV Repair Costs: An Increasing Trend

In industries like trucking, EV repair claims comprised 2.4% of all claims in early 2024, up from 1.6% in 2023.
The average EV repair cost is now approximately 46.9% higher than that of comparable non-EV vehicles.
Labor makes up around 43.3% of repair expenses for newer EVs, compared to 36.5% for conventional vehicles.

EV components are inherently more complex—modern EVs feature more parts per repair, longer cycle times, and higher labor hours:

EVs take about 4 more labor hours to repair than ICE vehicles, and involve replacing 22 parts per repair, compared to just under 16 for ICEs.

Innovations like gigacasting—casting large single-piece chassis parts—promise cost reductions in manufacturing but escalate body and battery repair costs by up to 30% by 2027.

Insurance premiums for EVs are typically 26–44% higher than for gas vehicles, driven by higher vehicle values, specialized repair needs, and battery complexity.
Certain components can be notably expensive:
“The complexity of certain parts compared to their ICE counterparts … the AC compressor … costs around $2,750 with labor … ICE counterparts can be had for between $660–$1,100.”
This highlights the scarcity of affordable aftermarket parts and the high costs of OEM replacements.

hyper realistic of electric car charging on a gas station

Despite rising repair expenses, EVs continue to offer maintenance advantages:

EVs are mechanically simpler, with as few as 20 moving parts versus over 2,000 in ICE vehicles — reducing the need for routines like oil changes, filters, and belts.
Regenerative braking extends brake life significantly; EV batteries require minimal routine maintenance and often come with 8–10 year warranties, while battery degradation averages only 1.8% per year.
One analysis found EV maintenance and repair costs are about half those of ICE vehicles.
In the U.S., operating costs average about $0.04 per mile for EVs—amounting to $8,000 in savings over the vehicle’s lifespan compared to gas cars.

Smart diagnostics & predictive maintenance are becoming mainstream—battery health monitoring, OTA updates, and real-time analytics are improving reliability and reducing unexpected failures.
Specialized EV service centers are proliferating, staffed with trained technicians who know EV systems inside and out.
The EV maintenance market is booming—projected to grow from $13.4 billion in 2024 to $15.3 billion in 2025, with expectations to reach $25.5 billion by 2029.
Sustainability efforts are on the rise—service centers are embracing recycling practices, renewable energy, and 3D-printed parts to reduce environmental impact.

Legislative momentum is growing in favor of Right-to-Repair, giving EV owners and independent shops access to vital tools, software, and parts. This includes bans on restrictive practices like parts pairing.
Greater access and transparency could help curb repair costs and improve accessibility—especially in underserved areas.

EV ownership in 2025 offers real savings in routine maintenance and operational costs, but owners should be prepared for higher repair and insurance bills, especially post-warranty or after serious damage.
The good news? As infrastructure, legislation, and training evolve—and with innovations like predictive maintenance and 3D printing—EV service is becoming more efficient, accessible, and greener.
For prospective buyers: balance the long-term operational savings with upfront repair and insurance considerations, and stay informed about service network availability and warranties.