The shift to EVs and its impact on fleet repair and maintenance

The automotive industry has evolved rapidly over the past five years, more so than in the last few decades. One of the key drivers being the shift to electric vehicles (EVs)—a trend that continues to gain momentum. Fleet managers in the UK are increasingly navigating the transition from internal combustion engine (ICE) vehicles to EVs. While this shift supports sustainability, it also brings new challenges in repair and maintenance, as EVs require specialised knowledge that not all repairers possess. With fleet managers already under pressure to manage downtime and operational costs, the shift to EVs is proving to be a pivotal challenge for many in the industry.

The growing EV fleet landscape

The push toward electrification is gaining momentum in the UK, with government initiatives and sustainability goals driving the demand for EVs. Fleet operators are a key player in this shift. The UK government’s 2035 ban on new petrol and diesel vehicles has accelerated the adoption of EVs across sectors like logistics, corporate fleets, and public transport.

However, while the benefits of EVs are clear—lower emissions, reduced fuel costs, and quieter operation—fleet managers are now discovering that the repair and maintenance processes for electric vehicles differ significantly from traditional ICE models. As fleets increasingly incorporate EVs, the complexity of maintaining and repairing these advanced systems grows. EVs require specialised knowledge, equipment, and safety protocols, particularly in managing high-voltage components and battery systems. As a result, the repair landscape is undergoing a transformation, and this is presenting new challenges.

Image: Fixico

While EV charging remains a hot topic, EV repairs are an overlooked challenge

This year’s edition of Fleet & Mobility Live was packed with charging solutions, reflecting the industry’s focus on EVs. However, a critical gap remains in the conversation: EV repairs. While many companies are racing to provide charging infrastructure, the challenge of repairing EVs has been largely overlooked. Attendees we spoke to acknowledged this issue, pointing out that without an effective repair solution, the transition to EVs could slow down.

Repair and maintenance: A new set of challenges

EVs differ significantly in design: without an internal combustion engine, they have fewer moving parts, which theoretically reduces maintenance needs. However, they introduce new complexities:

1. High-voltage batteries and electrical systems

Repairing or replacing high-voltage batteries poses challenges for workshops, as EV systems require specialised training and equipment that traditional body shops often lack. This can lead to increased downtime and higher repair costs

2. Specialised parts

Sourcing parts for EVs is not always as straightforward as for ICE vehicles. While the supply chain for EV parts is expanding, it still presents a bottleneck for some repairers. Parts, like batteries and charging systems, can take longer to procure, contributing to longer repair cycles.

3. Training and certification

Many repairers lack the necessary training or certifications to work on EVs. Given the risks of high-voltage systems, specialised training, safety protocols, and in some cases, certification are essential. This skills gap is pronounced in the UK, where demand for qualified EV technicians exceeds supply.

4. Infrastructure shortcomings

While the UK has made significant strides in installing an EV charging infrastructure, there are still gaps, particularly in repair networks. Many body shops are still unequipped to handle EV-specific needs, such as high-voltage battery replacements or advanced diagnostics, which means that fleet managers may have to search farther for capable repair centres.

Image: Fixico

Impact on repair costs and cycle times

One of the growing concerns for fleet managers in the UK is the higher repair costs and longer cycle times associated with EVs compared to traditional ICE vehicles. As previously mentioned, a key issue is the availability of EV parts, which can lead to significant delays in the repair process. According to the National Body Repair Association (NBRA), in an interview with Autoexpress, the UK’s EV parts supply chain is still developing, making it harder to source components, especially for newer or less common models. This results in longer off-road times for EVs, while ICE vehicles benefit from faster and cheaper repairs due to an established supply chain. As EV adoption grows, solving these issues is key for fleet efficiency and cost control.

Mitigating downtime with digital solutions

For fleet managers, the impact is twofold: increased complexity in repairs and extended downtimes, which can quickly lead to higher operational costs. Digital repair management platforms offer a solution by simplifying the repair process and reducing these bottlenecks.

Leveraging a marketplace of specialised repairers provides fleet managers with access to EV-capable body shops trained and equipped to handle the complexities of EVs. Through a digital damage intake process, customers can have their vehicle’s damage assessed remotely, saving time and eliminating the need for physical inspections. Additionally, platforms that use AI-driven repair allocation ensure that each repair is directed to the most suitable repairer, reducing both repair cycle times and vehicle downtime.

Furthermore, real-time insights into the repair process allow fleet managers to monitor repair statuses, review costs, and anticipate vehicle readiness—enhancing efficiency as EV adoption grows.

Looking ahead: Future-proofing repair networks

As the automotive industry evolves, it’s clear that fleet operators and repairers alike need to adapt. Future-proofing UK repair networks to meet the growing demand for EV repairs is essential. Investment in training, equipment, and infrastructure is needed to ensure that fleet managers can transition their fleets without compromising on repair quality or speed.

Many repairers are already beginning to pivot, offering specialised EV services and seeking certifications to cater to this rising demand. However, the pace of adaptation varies across the UK, and more needs to be done to ensure that repair networks can support fleet electrification on a national scale.

Conclusion: Navigating the EV transition

The shift to electric vehicles presents fleet managers with both opportunities and challenges. While the long-term benefits of EVs are undeniable, the immediate challenges of repair and maintenance cannot be ignored. For UK fleet operators, finding the right repair partners, ensuring minimal downtime, and managing costs will be key to a successful transition.

Author: Charles Crosby, Network Manager UK, Fixico