10 Most Common EV Reliability Issues And How To Avoid Them

ICE vehicles have been in use for well over a century, and we know where we stand with them. EVs in their modern guise have been around for about 25 years, and only really started becoming quite common over the last seven or eight years.

Battery Degradation Over Time

Most EV batteries come with a guarantee of 100,000 to 150,000 miles, but batteries degrade over time. Although the rate of degradation will vary depending on the car brand, the age of the battery, prevailing weather conditions, and how it is used, an EV battery on average degrades at around 2.3% per year.

The Signs Of Battery Degradation

Because EV battery degradation is a slow process that happens over time, it is often difficult to notice. The most obvious signs are:

• Reduced driving range over time.
• Longer charging times.
• Lower performance in extreme weather, including loss of range in cold weather and overheating in hot conditions.

How To Mitigate Battery Degradation

Stick to optimal charging levels to avoid stressing the battery. Don't run it completely flat and don't charge it over 80%, especially not with a quick charger. So keep your battery charge between 20- and 80-percent. EV batteries are sensitive to extreme temperatures, and battery life can be extended by avoiding these. Where possible, park in shade or temperature-controlled areas like parking garages.

Much of the battery maintenance over its lifespan is carried out automatically in the background by battery management software. Make sure your software is regularly updated, especially when the car gets older.

Reduced Range In Extreme Weather Conditions

All engine types are affected by really cold weather, but EVs more so than ICE. An internal combustion engine creates more heat than it needs and has to shed some of it via cooling. Some of that excess heal can also be used to heat the inside of the vehicle. EVs have several drawbacks in the cold:

• Freezing weather will slow the chemical reactions inside the EV battery, reducing the amount of charge it can hold and its discharge ability.
• Charging points can also be affected, resulting in less efficient charging and longer charging times.
• In extreme cold, the battery has to heat the inside of the vehicle as well, resulting in a loss of range.

How To Reduce The Effects Of Cold Weather

• Warm up the vehicle while it is still plugged into the charger, so more of the battery power can go towards maximum range.
• Use seat warmers rather than cabin heating, as these use less energy from the battery.
• Even using the precautions above, low temperatures will still sap battery performance, and you should plan the route with charging stations in mind.

Charging Infrastructure Limitations

Two of the most common issues slowing EV uptake are range anxiety and lack of charging infrastructure. Range anxiety is reduced when the EV driver has confidence in their ability to recharge when the battery runs low.

EV Charging Infrastructure

States like California boast some of the best charging infrastructure in the world, and most major urban areas in the US are well catered for as well. Charging infrastructure development, however, has not kept up with the increased use of EVs, and many drivers experience charging issues:

• Lack of charging stations off the beaten track.
• Charging station fittings not compatible with all EVs.
• Slow charging speeds because of dated equipment.
• Unreliable equipment at charging stations.
• Payment difficulties.

How To Overcome Charging Station Limitations

The average daily commute in the U.S. is 37 miles, so unless a longer trip is planned, charging infrastructure should not be an issue. The best way to solve the problem is to use public charging as little as possible. Install a home charger, which is a simple and convenient overnight solution. One can also push for workplace charging facilities to be installed.

There is an app for everything, including EV charging. Find a good one to locate nearby charging stations, and the app should also resolve any payment difficulties.

In-Car Electronics Failures

While an EV's drivetrain is far simpler and uses fewer mechanical moving parts than that of an ICE, modern EVs are complex electrical and electronic systems and these can malfunction due to various reasons. All vehicles use complex electronics, and will stop working or operating optimally when these systems stop working.

Electronic In-car EV Failures

Some electronic failures are a nuisance, while others could affect safety. Windows can stop winding up or down, or doors can fail to lock or unlock properly. Other failures could be critical, such as temperature sensors that ensure your battery is working within safe limits. While any electronic failure should be fixed as a matter of urgency, EV drivers can take specific steps to keep their cars going safely.

Keeping EVs Electronics Functioning

• Keep software updated to fix problems and improve overall performance.
• Keep to scheduled maintenance to identify problems early.
• Fix electronic glitches promptly, as these can go critical at any time.
• Stick to OEM-approved accessories to avoid malfunctions.

Tire Wear Due to Instant Torque, Weight

EV tires wear out more quickly than the tires on similar ICE vehicles. Even accounting for differences in driving styles, EV tires generally wear out around 20-percent faster than other vehicles.

Reasons EV Tires Wear Out Faster

EVs are heavier than similar ICE cars, because of the weight of the batteries. The heavier the vehicle, the more friction there will be between tires and road during acceleration, braking, and cornering. EVs have more torque than similar ICE vehicles, and spirited acceleration will cause wheel spin more quickly. The tires on EVs are designed for low rolling resistance and reduced road noise, and this could make them less durable than other tires.

How To Lower EV Tire Wear

• Rotate the tires regularly to ensure all the tires wear evenly over time.
• Make sure the tire pressure is right at all times, as this keeps the tire properly on the road and lowers uneven wear.
• Moderate your driving style - this applies to any vehicle - as rapid acceleration, sharp cornering, and sudden stops all run through your rubber.

Brake System Maintenance

EVs use one-pedal braking to recoup energy expended during acceleration, but they do have traditional brakes for use during spirited driving or emergency stopping. Because of the nature of an EV versus an ICE vehicle, and the way we drive them, EV brakes need a bit of extra care and attention.

Causes Of EV Brake Problems

EV brakes suffer problems because they have to work too hard, or they are seldom used. EVs are heavier than similar ICE vehicles, so any braking with the discs and calipers will require more force, causing more friction, and thus faster wear.

Conversely, one pedal braking uses the motor to slow the vehicle while extending the range. If used exclusively, the brake system is underused. Corrosion can form on the discs and pads, while the whole system can become stale through lack of use.

Solving EV Brake Problems

• Regular inspection to make sure everything still works.
• Using the normal brakes every now and then to stop corrosion and make sure the moving parts will keep moving.
• Using the vehicle regularly will keep the brakes and all other systems in good shape.

Software Glitches

All cars are loaded with software, but EVs seem to have turned into large, mobile computers. As a result, even though EVs are far simpler and have fewer moving parts than other cars, they account for a significantly greater percentage of repairs than other cars.

EV Software Problems

Software problems plaguing EVs are not really different from those of other cars, but for some reason, they seem to be more prevalent. These problems can be annoying, like malfunctioning infotainment screens, to potentially dangerous, as when driver aid alerts go haywire. It can also be dangerous, when the engine or brake management system stops working properly.

Solving EV Software Problems

• Accept all updates when they arrive.
• Report problems to the dealer or manufacturer.
• When in doubt, reboot the system.

Limited Towing Capacity

EVs are not great at towing boats, trailers, or caravans. It really cuts down on their range, and range is a critical issue when it comes to EV acceptance. It comes down to the difference between how EVs and other vehicles work.

Why Towing Cuts EV Range

EVs work on a different set of physical calculations compared to ICE or hybrids. Whereas ICE vehicles use more fuel in the city than on the freeway, EVs are more efficient in stop/start driving than ICE. That is because they recover energy during braking, while ICE vehicles do not. On the open road, the EV recovers nothing and is subject only to the aerodynamic drag that increases exponentially with speed.

An EV towing a trailer in town should do well, with the weight of the trailer adding to the regenerative braking, while the lower urban speeds will not give such a heavy aerodynamic penalty. On open roads, where towing range is the issue, the additional drag caused by the tow will not be recouped through braking.

How To Tow With Your EV

• Work within the manufacturer's specifications.
• Use EVs optimized for towing.
• Plan your route to suit your load.

Battery Fires

New technology that could go bang does stoke fear in people. So it is with EV battery fires. An EV battery fire involves thermal runaway, a chemical process when a battery cell short circuits and gets really hot. This causes a fire that makes the other cells in the battery burn as well.

The Good News About EV Battery Fires

EV battery fires are really rare. There were around 500 such fires globally from 2010 to 2024, so 1 in 100,000. Tesla reckons one fire for every 130 million miles. Non-EVs, according to a Swedish study, estimated that gas and diesel cars were 29 times more likely to catch fire than an EV.

How To Avoid EV Battery Fires

• As with any other car, try and avoid crashing.
• Pay attention to recalls.

High Repair Costs

There is a perception that EV repairs are significantly more expensive than other vehicles. Although EVs generally have fewer things that can go wrong, when something like a battery pack has to be replaced, that would be a very high expense.

Economies Of Scale

The real expense in EV repairs resides in economies of scale. There are thousands of ICE repair shops for each EV one, tens of thousands of ICE mechanics for every EV specialist. Parts are manufactured in much smaller quantities than for common ICE use, so unit costs will be higher.

That said, EV costs are coming down, and the percentage of EVs on the road is growing. At some stage in the future, price parity will be reached, and after that, EV repairs will drop to way below that of ICE.

High Repair Costs In The Meantime

• Consider your EV's warranty and invest in an extended warranty if it seems lacking.
• Stick to the recommended maintenance schedule to avoid expensive repairs.
• Choose certified repair shops, even if they are more expensive.