Growing vehicle complexity increases fleet maintenance headaches

July 23, 2026

Modern vehicles are becoming more sophisticated, but that complexity is creating new challenges for fleet operators, according to the Association of Fleet Professionals (AFP).

The organisation says fleet managers are seeing an increase in faults across both ICE and electric vehicles, with many leading to vehicle downtime, safety concerns and lengthy discussions with manufacturers.

The most commonly reported issues include:

Traction battery faults
Electronic handbrake failures
Tyre-related issues
Windscreen sensor and software faults
Alarm system problems

The AFP says sharing experiences between fleet operators is helping demonstrate that many faults are not isolated incidents, giving fleets greater leverage when raising issues with manufacturers. However, support remains inconsistent, with some OEMs praised for their response while others continue to struggle with parts shortages, limited technician capacity and slow warranty repairs.

FleetWise takeaway

When reviewing your next vehicle shortlist, look beyond purchase price and whole-life cost. Consider:

Aftersales support and manufacturer responsiveness
Dealer and technician network coverage
Parts availability
Warranty response times
Telematics and predictive maintenance tools that can identify issues before they lead to costly downtime

As vehicles become increasingly software-driven, the quality of manufacturer support is becoming just as important as the vehicle itself when it comes to maximising uptime and minimising fleet disruption.