New warranty claims data from Warranty Solutions Group (WSG) highlights a growing issue for van fleets: downtime, not repair cost, is now the biggest operational risk.
Analysing more than 1,000 light commercial vehicle claims from 2025, WSG found that the most expensive failures were linked to engines, turbochargers, diesel particulate filters (DPFs) and electronic control units (ECUs), with the single highest claim exceeding £6,000. Crucially, most high-value claims involved vans aged four to nine years, after manufacturer warranties had expired.
Mark Bobbins, head of commercial vehicle sales at WSG, said: “Every hour a van is off the road directly affects productivity and profitability.”
Below are the most common LCV claims according the WSG.
For fleets running leaner operations and extending replacement cycles, this data reinforces the need to plan beyond headline repair costs. Specialist diagnostics, parts availability and workshop capacity are now just as critical as warranty cover.
For operators, the takeaway is clear: maintenance planning, contingency vehicles and downtime modelling should be treated as cost-control tools, not afterthoughts — particularly for ageing diesel fleets still critical to daily operations.
Explore FleetWise's telematics and tracking guide, and how real-time vehicle health data can help fleets spot engine and emissions issues early.
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