Used EV Repairs More Common for Non-Battery Components, Study Finds
Research by Warrantywise reveals electrical system faults and charging issues are more frequent than high-voltage battery problems in pre-owned electric vehicles.
Common repair requests for used electric vehicles (EVs) primarily involve non-powertrain components, with issues related to the high-voltage battery being relatively uncommon, according to new research. Data from used car warranty provider Warrantywise indicates that electrical system troubles are the leading cause of repairs for second-hand EVs.
Electrical system issues, such as sensor malfunctions and central locking failures, topped the list of repair requests analyzed between January 2023 and January 2026. Sensor repairs averaged $809.59, with the highest recorded cost at $3,270. Central locking mechanism failures averaged $899.44, with a maximum repair cost of $4,056.82.
The on-board charger system emerged as the third most common fault, incurring a significant average repair cost of $2,158.75. The most expensive on-board charger repair documented reached $10,454.98. Suspension issues, specifically wishbone failures, ranked fourth with an average repair cost of $1,229.64 and a highest recorded cost of $4,118.65.
Another electrical system issue, the auxiliary battery (12V battery), was the fifth most frequent fault, costing an average of $532.94 to repair, with the highest cost being $986.15. Crucially, EV battery-related repairs did not feature in the top five reported issues by Warrantywise, suggesting that concerns about frequent, high-voltage battery failures in used EVs may be overstated.
"The main battery on an EV is understandably the first thing many used EV buyers think about, but our data shows that the everyday components still matter," said Antony Diggins, managing director at Warrantywise. "A good used EV purchase should include the same checks you would make on any used car, plus a closer look at charging systems."
This research comes as sales of used EVs continue to increase. The Society of Motor Manufacturers and Traders (SMMT) reported a 32 percent rise in used EV transactions in the first three months of the year. To address potential repair costs and provide peace of mind, an increasing number of EV owners are opting for extended warranties. Warrantywise reported a 68.2 percent increase in EV warranty sales between 2024 and 2025.