WSG reveals most common and costly van faults

June 24, 2025

Warranty Solutions Group has revealed the UK's most common and costly van faults over the last 12 months.
Alternators are the most commonly claimed-for part under UK light commercial vehicle (LCV) extended warranties, according to new data from Warranty Solutions Group (WSG). Based on 1000 warranty claims between July 2024 and June 2025, alternators accounted for 5.35% of all claims, with an average repair cost of £506.78.
Second on the list were NOx sensors (4.51% of claims, £558.68 average), followed by diesel injectors (3.67%, £613.29).

The Top 10 also included AdBlue injectors, diesel particulate filters (DPFs), batteries, EGR valves, dual mass flywheels, turbochargers and EGR coolers – all contributing to significant maintenance costs.

UK's most-reliable vans league 2025

WSG’s head of commercial vehicle sales, Mark Bobbins, highlighted the growing financial impact of emissions-related part failures. He said the data reflects how complex vehicle systems and environmental regulations are pushing up maintenance risk and repair costs. Strong warranty support and proactive servicing, he added, are now essential tools for risk management and uptime protection.

WSG also revealed that some van models had above-average claim rates. The Vauxhall Vivaro was rated least reliable, followed by the Peugeot Boxer and Ford Transit.

This real-time claims data helps operators identify common faults, guide vehicle choice and reduce the financial impact of unexpected downtime.