Electric cars

EV collision repair costs 20% more than for gas models

August 20, 2024

EV collision repairs continue cost more than those of internal combustion vehicles, according to a new report from Mitchell International, which provides tech for the auto insurance and collision repair industries.

The report, based on second-quarter 2024 data, shows similar rates of EVs and 2021-and-newer gasoline vehicles being declared total losses by insurance companies. EVs were declared not worth repairing in 9.16% of cases studied in the U.S., compared to 9.45% of newer gasoline cars.

Mercedes-Benz EQS SUV and EQA crash test

When EVs aren’t totaled, though, they cost nearly 20% more to repair than comparable gasoline vehicles, according to the report. EV repair costs averaged $5,753 in the U.S. in Q2, compared to $4,806 for vehicles with a combustion engine. The average repair-cost rates for hybrids and plug-in hybrids were $4,726 and $5,059, respectively, which Mitchell puts down to plug-in hybrids’ use of larger battery packs.

The rate of claims for EVs also increased 45% in the second quarter, the report found, although that’s to be expected as more vehicles join the fleet and are inevitably crashed. The newness of many EV models is also reflected in a higher use of OEM parts for repairs, at 89% of parts dollars spent compared to 65% for combustion cars.

Mercedes-Benz EQS SUV and EQA crash test

EVs do at least require less frame repair work, according to the report, likely the result of higher curb weights and battery packs that can act as structural reinforcements. However, mechanics spent more time in Q2 appraising EV repairs than those of combustion vehicles, at 8.18% and 5.21%, respectively.

The new report has similar findings to one published by Mitchell in 2023, which found that average repair costs for EVs in the U.S. were $963 higher than comparable gasoline cars. Hertz also cited high collision repair costs as the main reason for slowing its EV plans, and they continue to be a factor in why EVs cost more to insure than hybrids right now.