Why EV Repairs Still Take Longer Than Gas Cars

EV repair costs are declining, yet data from Mitchell and CDK show longer repair times and higher complexity compared with gas cars. Explore the full findings.

Repairing electric vehicles is gradually becoming less expensive, but it remains more complex and often slower than fixing cars powered by internal combustion engines. Recent data from Mitchell show that the average U.S. repair severity for battery electric vehicles (BEVs) fell from $6,707 to $6,395 year over year — a decline of about 5 percent. Even so, the gap with conventional vehicles persists, as comparable ICE models average around $5,105 per repairable claim.

At first glance, that trend looks encouraging. Yet behind the modest cost reduction lies a different dynamic: a growing volume of claims. According to the same report, repairable collision claims for EVs rose 14 percent in the United States and 24 percent in Canada. As more electrified vehicles reach the road, the pressure on the repair industry continues to build.

The core issue is structural complexity. Modern EVs are defined by dense electrical architectures, software-driven systems, and sensor-heavy designs. After a collision, shops must go beyond replacing damaged parts and perform additional diagnostic procedures and recalibrations. On average, BEVs require 1.70 calibrations per estimate, compared with 1.63 for hybrids and 1.54 for ICE vehicles. Each calibration adds time, labor, and cost.

Parts selection also plays a role. Mitchell reports that about 86 percent of parts dollars for BEV repairs are tied to OEM components, versus roughly 62 percent for ICE vehicles. At the same time, the share of repairable parts listed is lower for EVs. That combination tends to push overall repair bills higher.

Customer experience data reinforce the picture. Findings from CDK indicate that 34 percent of non-Tesla EV owners report longer service or repair times compared with gasoline vehicles, while 23 percent of Tesla owners say the same. The share of repairs completed the same day dropped from 40 percent to 28 percent year over year, and repeat visits have become more common.

German insurance data point in a similar direction, although the gap appears to be narrowing. According to GDV, average comprehensive claims for electric cars are currently about 15 to 20 percent higher than for comparable combustion models, down from a previously cited 20 to 25 percent range. Insurers attribute the shift in part to growing workshop experience and more established procedures, including safety measures related to high-voltage systems after accidents.

Importantly, higher collision repair costs do not automatically translate into higher overall ownership costs. Germany’s ADAC reports that routine servicing for electric vehicles is significantly cheaper — in its assessment, at least one-third less than for comparable ICE cars. With fewer moving parts and reduced maintenance requirements, EVs often offset their collision complexity with lower day-to-day service needs.

The result is a nuanced reality. Electric vehicles can be cheaper to maintain in regular use, yet more demanding and time-intensive when body repairs are required. As long as vehicles remain heavily digitized and reliant on advanced sensor systems, the repair ecosystem will continue adjusting to the technical demands of the electric era.