Electric Vehicle Maintenance and Repair: A Guide

As Electric Vehicles (EVs) sales continue to surge, and the first wave of mainstream EVs like the 2018 Tesla Model 3 begin to come out of their original manufacturer powertrain warranty, EV maintenance and repair has gotten more attention.

Until even a year or so ago, the prevailing story was that electric vehicles need no repair. This idea is now losing steam, as lines begin to stretch beyond OEM service shops and dealers and owners begin to share their own experiences across the EV ownership experience.

However, two introductory questions remain: if you have an EV, what can require repair and maintenance and can a regular auto mechanic do it? In this guide, we dive into both questions.

1. EVs DO need less maintenance

First of all: the story is certainly partially true: electric vehicles on the road today have less frequent maintenance needs than a gas-powered vehicle. Several Tesla owners we’ve interviewed at Axle, as well as across auto forums and Reddit, cite having done almost nothing to keep their vehicle in tip top condition. On average, the lower maintenance needs for EVs are due to the streamlined design of their drivetrains. Unlike traditional internal combustion engine (ICE) vehicles that come with elaborate engines, transmissions, and exhaust systems, EVs feature much fewer moving parts. Without oil changes, fluid checks, or exhaust replacements, EV owners enjoy cost-effective servicing and fewer trips to the mechanic for these aspects. Furthermore, EVs integrate regenerative braking systems that enhance brake longevity by transforming kinetic energy into electrical power, minimizing wear on brake pads.

2. But less Maintenance does not mean zero

However, it’s important to note that while maintenance on an EV is notably diminished, its not entirely eliminated. There are still service items that require frequent and proactive scrutiny. Tires is a big category. For instance, EV tires need more frequent replacement due to the vehicles’ heavier battery weight compared to their ICE counterparts.

3. Electric Vehicle (EV) Repairs Are More Complex

Additionally, if you’ve ever had a tire issue with a Tesla on a highway in Durham, NC (Ahem, that was our Head of Engineering) you may have noticed that in addition to Tesla saying they had no capacity, not every tow company and shop is even willing to come do a simple tire replacement. When EVs require repair, whether due to malfunctions in the system, regular wear and tear, or even collision-related damage, the repair process often proves to be more multifaceted. This complexity arises from the need for specialized parts – even some EV tires – and the balance of high-voltage electricity, high-tech software, and mechanical parts within an electric vehicle. As a result, working on an EV requires training and expertise that covers high-voltage safety and can frequently be very specific to the vehicle model.

The need for qualified and trained EV Technicians

EVs require specialized knowledge and auto mechanic and technician training is no longer just a nice to have, its a prerequisite to ensure the safety of everyone working on or around an electric vehicle. Given the high voltages that power these vehicles, failure to do so can have devastating consequences for personnel, which should be a primary consideration, but also property as risk for battery fires goes up with incorrect storage and repair procedures, particularly post-collision.

And today, with the rapid rise of electric vehicles and OEM repair centers beginning to struggle with having enough capacity to service them, the need for more EV expertise across shops beyond the manufacturer or dealer has started to emerge. EV technician training can be foundational and then gets more specific to the repair type itself. However, it can even be vehicle and model year specific with different OEMs like Tesla, Hyundai, Ford having very different service guides for vehicle repair and replacement. In the future automotive repair world, we expect technicians will have to specialize much more, to continue to diagnose and repair electric vehicles successfully versus in the ICE world where an intense level of specialization is not as frequently required.

EV Repair Types

In the rest of this guide, we explore the world of electric vehicle repair, encompassing high voltage safety measures and automotive repair essentials.

(1) Battery System

The battery system serves as the lifeblood of every electric vehicle, making its functionality paramount. Anyone worrying about an electric vehicle purchase, will frequently cite battery degradation, and even warranty expiration as one of their biggest concerns. Manufacturers are constantly improving this technology by leaps and bounds almost every month – with range, quality and reliability levelling up all the time. However, on the other end, a battery is only as good as its weakest cell. While repairs are rarely required, when needed, they can become urgent to ensure the drivability and efficiency of the vehicle. While all electric vehicle repair – even light maintenance – requires awareness training, any sort of battery repair or replacement is extra complex and requires even more extensive training and technician certification.

Issues with EV batteries

Some issues that commonly arise with EV batteries include:

1. Capacity Degradation: Over time, EV batteries can experience capacity loss due to factors like temperature fluctuations and frequent fast charging. Effective EV technician training equips professionals to address capacity issues through battery reconditioning or module replacement.
2. Cell Imbalance: The performance and range of an EV can be compromised due to imbalances in individual battery cells. Qualified EV technicians can mitigate this by balancing cells or replacing defective ones.
3. Thermal Management System: Malfunctions in the thermal management system can lead to overheating, affecting both battery efficiency and longevity. Thorough EV technician training and certification prepares professionals to diagnose and rectify cooling or heating element issues.

(2) Charging System

A well-functioning charging system is imperative for the optimal performance of an electric vehicle. Repairs within this system encompass:

1. Charging Port Issues: EVs can face charging hindrances due to faulty charging ports. EV technicians trained in high voltage safety protocols can expertly tackle issues like cleaning, connector replacement, or rectifying wiring complications.
2. Onboard Charger Problems: The onboard charger’s critical role in converting AC power to DC power for the battery cannot be overstated. Skilled EV technicians proficient in electric vehicle repair should be able to adeptly handle power conversion issues, fuse-related matters, or circuitry challenges as they arise. This requires a deeper understanding of the theory of electric fundamentals than many auto techicians may be used to.
3. Charging Cable Damage: The charging cable can experience wear and tear over time, leading to compromised connectivity. EV technicians with the requisite training can seamlessly replace or repair the cable, restoring efficient charging capabilities.

(3) Electric Motor and Drive Unit

The motor and drive unit(s) constitute the driving force behind an electric vehicle’s movement. Common issues that may arise include:

1. Inverter Malfunctions: The inverter plays a pivotal role in converting DC power from the battery into AC power for the motor. Proficient EV technicians can identify and resolve inverter problems, thereby averting power loss or inefficient performance.
2. Motor Issues: EV motors can experience complications with bearings, windings, or sensors. Skilled technicians can undertake motor component replacements or rewinding, ensuring seamless functionality.
3. Regenerative Brak-down (get it?): Regenerative braking systems capture kinetic energy during deceleration and transform it into electrical energy. Repairs within this system involve:
   1. Brake-by-Wire Problems: Regenerative braking relies on a brake-by-wire system. Expert EV technicians are equipped to diagnose and rectify any malfunctions, as they arise.
   2. Sensor Failures: Sensors responsible for monitoring vehicle speed and acceleration are pivotal for effective regenerative braking. EV technicians trained in electric vehicle repair can address sensor malfunctions through recalibration or replacement, optimizing energy recapture

(4) Electrical System

The holistic electrical system of an EV comprises multiple components, and issues can manifest in various forms:

1. Electrical Wiring Challenges: Damaged or corroded wiring can disrupt communication between components, affecting the overall functioning of the EV. Skilled EV technicians proficient in electric safety guidelines can expertly identify and rectify wiring issues.
2. Control Units Troubles: Diverse control units govern different aspects of EV operations. When these units malfunction, it can lead to erratic behavior or diminished performance. EV technicians can skillfully repair or reprogram control units, restoring optimal functionality.

(5) HVAC System

The heating, ventilation, and air conditioning (HVAC) system within an EV contributes to both passenger comfort and vehicle efficiency. Unlike an ICE vehicle, where hot air is a by-product of the engine, EVs requires considerably more effort with varying systems which we discuss in more detail in our EV systems overview course. Common repairs in this area include:

1. Coolant Leaks: Leaks in the coolant system can compromise HVAC efficiency and the overall thermal management of the vehicle. EV technicians trained in electric vehicle repair can adeptly identify and rectify coolant leaks.
2. Blower Motor Issues: The blower motor plays a pivotal role in distributing conditioned air. EV technicians proficient in electric safety protocols can troubleshoot and repair blower motor problems, ensuring optimal heating and cooling.

(6) Suspension and Braking System Repairs

While not exclusive to EVs, the suspension and braking systems are indispensable for vehicle safety. Repairs in these areas encompass:

1. Brake Pad Wear: Brake pads, similar to those in conventional vehicles, experience wear over time and necessitate regular replacement although at a much less frequent cadence. Skilled EV technicians are equipped to handle this maintenance requirement.
2. Suspension Component Failures: EVs are equipped with various suspension components that contribute to ride comfort and stability. Proficient EV technicians can replace worn-out parts, optimizing both ride quality and safety.

(7) Software and Firmware Updates

In contrast to traditional vehicles, EVs heavily rely on software and firmware for various systems. Regular updates can address bugs, enhance performance, and introduce new features. OEMs and manufacturers can actually do a lot of these over the air. You may have heard about massive recalls on thousands of EVs that were fixed overnight by the OEM through the push of a button!

(8 ) Vehicle Parts

At the end of the day, your electric vehicle is cool, but it is a car. Windshields will break during hail, door handles will jam, low voltage batteries will need jumpstarting, collisions will lead to dents and dings, and of course, small or serious accidents may happen. Almost every time something that breaks or dents or crumples will require scrutiny and even a different protocol for approaching and fixing it than what emergency responders and auto technicians are used to. For example, an EV that has gotten into a collision requires extra caution due to the high voltage system and a different post collision emergency response. Most EVs cannot also be towed.

Conclusion: EV = Car = Need Repair

So there you have it: in conclusion, EVs are very low maintenance, but not maintenance free and EV repairs can be complex. It’s essential to underscore that with everything, there is the importance of adherence to protocols. Technicians should never rely solely on their intuition or prior experience, as EVs introduce an entirely new realm of challenges. High voltage components and potential battery hazards require a level of caution and training that can’t be overstated. Regardless of their comfort level, technicians must receive proper training to ensure their safety and also the integrity of the repair. On the other end, customers may need to get more comfortable with the fact that as these repairs could be more complex and time-consuming, they may end up being costlier than what they are used to paying on the ICE vehicle side for a similar fault or malfunction.