Most costly light commercial vehicle repairs revealed
New research has uncovered the most common and most expensive light commercial vehicle repairs.
Warranty Solutions Group analysed data from more than 1,000 LCV claims between January and December last year.
The findings, published in its Commercial Vehicle Market View Report, found that the costliest claims were consistently linked to engines, turbochargers, diesel particulate filters, and electronic control units.
More specifically, diesel injectors and alternators together accounted for over eight per cent of all claims, with average repair costs of £622 and £543 respectively.
Batteries represented nearly three per cent of claims, while emissions-related components were also prevalent with the average cost of repair ranging from £323 to £885.
Meanwhile, vehicles aged four to nine years featured most prominently, underlining the financial risks operators face once manufacturer warranties expire.
Significant pressure
Mark Bobbins, head of commercial vehicle sales at WSG, said: “The commercial vehicle sector is under significant pressure in 2025, with spiralling costs, ongoing parts shortages, and regulatory demands all impacting fleet performance.
“For many operators, downtime has become the single biggest challenge, every hour a van or truck is off the road directly affects productivity and profitability. With leaner fleets and older vehicles staying in service for longer, the maintenance ecosystem is being stretched like never before.
“We are also seeing the growing complexity of modern vehicles drive new types of failures. While mechanical systems remain strong, emissions technology and onboard electronics are presenting operators with software faults, sensor issues, and diagnostic challenges. These are problems that not only require costly repairs, but also specialist skills and equipment to resolve quickly and compliantly.”
