The rise of electric vehicles (EVs) has paved the way for a cleaner future in transportation. However, as EV sales increase, concerns about the cost of repairing these cars—especially their batteries—have grown. Mechanics specializing in EV maintenance and repair have not shied away from sounding the alarm about the rising challenges of battery repair due to increasing costs and manufacturer-imposed restrictions. The real issue is not just fixing the cars but ensuring they remain sustainable and affordable in the long run.
Challenges in EV Battery Repair
The biggest issue in EV maintenance is the complexity of high-voltage battery repairs. Unlike traditional gasoline-powered cars, where a mechanic can easily replace a faulty battery component, EV batteries consist of hundreds of individual cells. When a battery fails, it does not necessarily mean the entire unit is defective—sometimes, only a few cells are damaged. This is where specialized mechanics are required.
To address this problem, shops like Cox Automotive and The Electrified Garage have started focusing on high-voltage battery repairs by diagnosing faulty modules instead of replacing the entire pack. This approach has reduced waste while significantly extending the lifespan of EV batteries. However, mechanics warn that repairs are becoming increasingly complicated as battery technology continues to evolve.
The Risks of Repairing EV Batteries
Repairing EV batteries is also dangerous, and experts warn that it should not be attempted at home or by an untrained individual. Battery cells can cause short circuits, leading to fire or explosions, and if a person is not wearing high-voltage gloves, they risk electrocution. Even e-bike batteries contain enough current to be fatal.
Repair vs. Replacement Concerns
In an interview with Rich Benoit, owner of The Electrified Garage, which specializes in Teslas, he stated that repairing an EV battery can cost as much as $10,000, while a new battery costs around $15,000. These expenses can increase further due to labor, taxes, and additional costs such as shipping.
Manufacturers Are Making Repairs More Difficult
Research conducted by various automotive experts suggests that some manufacturers have made EV repairs more complicated by designing batteries in a way that makes them nearly impossible to fix. Some EV models are built with sealed battery packs, meaning that even if only one module is faulty, it cannot be removed and replaced. Instead, the entire pack must be replaced. Additionally, some manufacturers use proprietary software that prevents third-party mechanics from accessing diagnostic information, making independent repairs difficult.
The Push for More Repairable EVs
Companies like Renault in Europe and Cox Automotive in the US have demonstrated that repairing and refurbishing batteries is a viable alternative to costly replacements. Making EV batteries more repairable would lower costs, reduce waste, and decrease the environmental impact by minimizing the materials needed to manufacture new ones.
What to Expect in the Future
As EV adoption continues to rise and technology advances, EV repairs will likely become even more complex. It is also uncertain whether third-party repair services will remain viable and independent of manufacturers. These uncertainties, along with the lack of affordable repair options, could make EV ownership less appealing and undermine the environmental benefits of electric cars due to the premature disposal of batteries.
Due to these reasons, mechanics are sounding the alarm that several issues in the EV industry need to change. Whether it’s lowering costs of repair, making repairs easier by creating better repair-friendly designs or having fewer manufacturer restrictions, making EV repairs possible will be crucial to the long-term success of EV vehicles.