Written by Morgan Ellis, Editor at GearUp Insights | About the Editor | Last reviewed: July 2026
3. Common Repairs and Potential Issues
Routine maintenance is only part of the picture. The bigger financial risk for either vehicle type comes from unplanned repairs — and here, EVs and gas cars fail in very different ways.
Gas Car Repair Risks
Internal combustion engines have hundreds of moving parts, and the repair risk grows steadily with age and mileage:
- Transmission failure: $2,500–$5,000. Most common past 100,000 miles, especially on vehicles that skipped fluid changes.
- Major engine repair: $3,000–$7,000+. Timing chain/belt failure, head gasket issues, or catastrophic wear can total the value of an older vehicle.
- Alternator or starter replacement: $400–$900.
- Exhaust system repair: $500–$1,500, more common in states that use road salt.
- Timing belt/chain replacement: $500–$1,200, typically scheduled around 60,000–100,000 miles.
EV Repair Risks
EVs have far fewer wear-prone parts, but the parts they do have can be expensive when something does go wrong:
- Battery pack replacement (out of warranty): $5,000–$16,000 depending on model and pack size. This is rare within the warranty period (see below) but is the single largest cost risk for an older, out-of-warranty EV.
- Drive unit/motor replacement: $1,500–$5,000. Uncommon — EV motors have a fraction of the moving parts of a combustion engine.
- Charging port or onboard charger repair: $300–$1,200.
- 12V auxiliary battery replacement: $150–$250 (every EV still has a small 12V battery for accessories, separate from the main pack).
Analysis: The pattern is consistent — gas cars accumulate a wider variety of smaller-to-medium repair risks throughout ownership, while EVs concentrate their risk in one expensive component (the battery pack) that is, for most owners, covered by warranty for the years they'll actually own the car.
4. Warranty Coverage Comparison
Warranty coverage is what actually determines whether the repair risks above come out of your pocket. This is where EVs have a structural advantage.
| Coverage Type | Gasoline Car (Typical) | Electric Vehicle (Typical) |
|---|
| Bumper-to-bumper | 3 years / 36,000 miles | 3 years / 36,000 miles |
| Powertrain | 5 years / 60,000 miles (some brands offer 10yr/100k) | N/A — see battery warranty |
| Battery warranty | N/A | Minimum 8 years / 100,000 miles (federally mandated for EV battery packs) |
Source: Manufacturer warranty documentation; federal EV battery warranty minimum per Clean Air Act emissions-related component rules.
Analysis: The federally mandated 8-year/100,000-mile minimum battery warranty means the single most expensive potential EV repair is covered for most of a typical ownership period. A gas car's powertrain warranty, by contrast, usually expires well before the vehicle reaches the mileage where transmission or major engine repairs become likely.
5. Long-Term Maintenance Cost Projection
Combining the routine maintenance figures from Section 2 over a 5-year ownership period:
| Cost Category | Gas Car (5-Year) | EV (5-Year) |
|---|
| Routine maintenance (low estimate) | $2,100 | $1,125 |
| Routine maintenance (high estimate) | $6,325 | $2,675 |
| Major repair risk (out-of-warranty) | Moderate — rises after year 4–5 | Low — battery typically still under warranty |
Figures are routine maintenance only, based on Section 2 annual estimates × 5. Major repair risk is not added as a dollar figure since it is highly model- and usage-dependent — see the repair risk breakdown above.
Analysis: Over 5 years, an EV owner can reasonably expect to spend $1,000–$3,600 less on routine maintenance than a gas car owner, before factoring in the lower major-repair risk during the battery warranty period. This is consistent with the 60% maintenance cost reduction commonly cited for EVs, though the actual percentage varies by model and driving conditions.
What This Means for Drivers
If you plan to keep the car within the battery warranty period (8 years/100,000 miles), the maintenance cost advantage of an EV is close to its theoretical maximum — you get the routine savings without meaningful exposure to the one large EV repair risk.
If you plan to keep a gas car past 100,000 miles, budget for a higher chance of a major repair (transmission, engine) landing outside any warranty coverage.
If you're buying used, check remaining battery warranty coverage on an EV the same way you'd check remaining powertrain warranty on a gas car — it materially changes the repair risk math.
The Bottom Line
EVs cost meaningfully less to maintain than gasoline cars — routine maintenance savings of $400–$700 per year are well supported by AAA and manufacturer service data, and the elimination of oil changes and reduced brake wear are structural advantages, not marketing claims. The bigger financial question isn't routine maintenance, though — it's warranty coverage on the one expensive EV component (the battery) versus the accumulating repair risk on an aging gas engine and transmission. For most owners who keep a vehicle within typical ownership windows, that comparison favors the EV.
Sources
Data reflects conditions as of June–July 2026. Prices and rates are subject to change. This analysis is for informational purposes only and is not financial advice.
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