INDIANA – A new study by car auction platform eCarsTrade reveals that electric vehicles (EVs) face significantly more initial issues than gas-powered cars, with the Tesla Model 3 identified as the EV most likely to require repairs.
According to the analysis of insurance repair claims and battery performance:
- EV Reliability: EVs experience 266 issues per 100 cars in their first year—over 40% more than gas-powered vehicles.
- Tesla Model 3: The Model 3 topped the list of EVs most likely to end up in the repair shop, with 29.61% of insured owners filing repair claims. Owners most frequently report issues with build quality, specifically gaps in panels and paint defects.
- Least Reliable Brand: Tesla was found to be the least reliable EV brand overall, with four of its models (Model 3, Model Y, Model S, and Model X) ranking among those with the highest repair claim rates.
Top EV Models Prone to Repair Claims
The study ranked vehicles based on the percentage of insured cars that made claims for repairs. The data also highlighted the most common issue for each model:
| Model | Repair Claim Rate (%) | Average Battery Capacity (kWh) | Top Reported Issues |
| Tesla Model 3 | 29.61% | 75.3 | Panel gaps and paint quality |
| Tesla Model Y | 27.32% | 72.4 | Suspension Problems and High Repair Costs |
| Ford Mustang Mach-E | 5.82% | 83.5 | High-Voltage Battery Junction Box (HVBJB) Failures |
| Tesla Model S | 5.38% | 96.7 | Door Handle Malfunctions |
| Hyundai Kona EV | 4.61% | 56.7 | Battery Recall and Charging Issues |
Battery Performance Concerns
The analysis also focused on battery capacity, which impacts the likelihood of needing an expensive replacement:
- The Nissan Leaf was found to have the weakest battery performance among the models studied, with an average capacity of just 51 kilowatt-hours (kWh). Most owners report issues with CHAdeMO fast charging failure.
- The Tesla Model Y, which came in second for repair claims, was noted to have a slightly lower battery capacity (72.4 kWh) than the Model 3, making it more prone to requiring replacement.
eCarsTrade noted that EV owners often face unique challenges, stating that understanding these trends is crucial for drivers, insurers, and manufacturers alike to ensure long-term reliability, safety, and a seamless ownership experience.
