Most common LCV repairs revealed by WSG
The most common LCV repairs and the models most likely to fail have been revealed by new research carried out by Warranty Solutions Group.
The findings are based on a sample of 1,000 extended warranty claims the company paid out between July 2024 and June this year.
The data revealed that the most common LCV warranty claims in the last year were for alternators, which accounted for 5.35% of all claims and cost on average £506.78 per repair.
This was closely followed by NOx sensors (4.51%) and diesel injectors (3.67%), highlighting the high incidence of faults related to emissions systems and engine performance in commercial vehicles.
Highest claim
Meanwhile, the highest single claim was £6,086 for a Mercedes Sprinter 316 CDI with engine-related faults. The second highest claim was £4,950 for a Citroen Berlingo with various engine faults.
Volkswagen’s Transporter models made the top 10 list twice, with issues ranging from gearbox mechatronic failures to DPF replacements, while the Vauxhall Vivaro was another repeat offender, with two separate models making the list due to engine and DPF issues.
Repair trends
Mark Bobbins, head of commercial vehicle sales at WSG, said: “What we’re seeing is a growing pattern: emissions-related components like NOx sensors, EGR valves, and AdBlue injectors are not just expensive to replace, they’re also failing more often. This isn’t just a technical issue – it’s a financial one.
“With environmental regulations tightening and vehicle systems becoming more complex, the cost of non-maintenance is rising fast. Proactive servicing and strong warranty support are no longer optional, they’re essential for managing risk and maintaining fleet uptime.
“In the current economic climate, one major repair can knock profitability off course. That’s why understanding which parts fail most, and planning accordingly, can make a measurable difference to a fleet’s bottom line. Our live claims data helps operators make smarter decisions about vehicle selection, servicing, and protection.”
Financial impact
He continued: “Our findings also point to a significant financial impact when faults do occur, particularly with components such as the diesel particulate filter (DPF), which carries the highest average claim value at £1,303.75.
“Other high-cost claims include the dual mass flywheel (£943.48), turbocharger (£872.89), and EGR cooler (£850.98), suggesting that even lower-frequency faults can result in substantial out-of-pocket expenses for operators if not covered by warranty.
“These findings underline the importance of robust maintenance routines and comprehensive warranty coverage for LCV fleet operators.”
