Warranty analysis offers timely reassurance for fleets weighing up used electric vehicles, while also underlining where costs can still bite. Research from Warranty Solutions Group, based on 1,000 real-world EV repair claims made during 2025, shows wide variation in both fault rates and repair severity across popular models.
The Nissan Leaf emerged as the most reliable used EV, recording a claim rate of just 1.52% and an average repair cost of £818. Common issues included lane assist cameras, shock absorbers and steering wheel switches. The Audi E-Tron followed with a 3.23% claim rate and one of the lowest average repair bills at £570. Completing the top five were the Vauxhall Corsa Electric (4.76% / £702), Ford Mustang Mach-E (5.26% / £2,242) and Tesla Model 3 (6% / £625).
At the other end of the scale, higher claim rates were seen on larger, premium models including the Tesla Model S, Mercedes EQB and Tesla Model X. Across all EVs, suspension-related faults dominated claims, reflecting heavier vehicle weights, while air conditioning and charging components proved among the costliest to fix.
Martin Binnee, operations director at Warranty Solutions Group, said the data shows EV ownership is “more complex” than often assumed, reinforcing the need for fleets to consider reliability history and protection alongside headline running cost savings.
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