The most expensive EV repairs (and how to avoid them)

If you drive an electric vehicle (EV), you probably love the low running costs and smooth, quiet ride. But here’s the thing: some electric car repairs can be shockingly expensive. Knowing which EV repairs cost the most—and how to prevent them—can save you thousands.

Why are some EV repairs so expensive?

While EVs have fewer moving parts than traditional cars, the parts they do have are high-tech, brand-specific, and pricey. Common reasons for high electric vehicle repair costs include:

• Advanced technology and strict safety standards.
• A shortage of certified EV mechanics.
• Parts that can’t be repaired—only replaced.
• Limited availability of universal components.

The 5 most expensive electric car repairs

1. EV battery replacement

The EV battery is the most expensive part of an electric car. Replacing it can cost €10,000 or more, depending on the brand and model. Even minor damage may require replacing the entire battery pack.

2. Electric motor and inverter repairs

While rare, a faulty EV motor or inverter can mean a complete replacement, often costing several thousand euros.

3. Onboard charger and high-voltage cable repairs

Charging systems—including the onboard charger, high-voltage cables, and connectors—are expensive to fix due to strict safety regulations.

4. Battery cooling system repairs

Batteries need precise temperature control. Repairs to the EV battery cooling system can be costly because of specialized parts and extra strain on the AC system.

5. EV bodywork repairs

Many EVs use large cast aluminum body parts. They’re lightweight but expensive to replace—sometimes leading to a total loss after even a small accident.

Other costly EV repairs

• Electric Door Handles – Motorized, retractable handles can cost €600–€1,000 each.
• Tires and Suspension – EVs are heavier and wear through tires faster. EV-specific tires are more expensive than regular ones.

How to avoid expensive EV repair bills

• Schedule regular maintenance with a certified EV technician.
• Avoid potholes, curbs, and speed bumps to protect the battery.
• Maintain proper tire pressure and replace worn tires early.
• Choose EV insurance that covers battery and electronics.
• Consider an extended warranty for high-cost components.

The bottom line

EVs are cheaper to run than gas cars, but battery replacement costs, bodywork repairs, and high-voltage component fixes can be budget-breakers. By understanding the risks, insuring smart, and maintaining your EV properly, you can enjoy all the benefits of electric driving—without the shock of a massive repair bill.