The Real Cost of Keeping Vans On The Road

New Report Highlights Common Van Repair Issues 

When you run vans for your business, you may already be well awarek that repairs aren’t getting any cheaper.

A new report from Warranty Solutions Group (WSG), based on more than 1,000 light commercial vehicle warranty claims, puts some hard numbers behind what many operators are already feeling.

The findings show that engine, emissions and electrical faults are now the biggest causes of costly repairs and downtime.

And in many cases, repair bills are pushing right up to, or beyond, typical warranty limits.

Where the money is really going

The most expensive claims analysed by WSG regularly ran into the thousands.

The single highest claim topped £6,000 on a Mercedes Sprinter, with other high-value repairs linked to well-known brands including Ford, Volkswagen, Peugeot and Nissan.

Engines, turbochargers, DPFs and electronic control units featured time and again, and aren’t quick fixes – they often take vehicles off the road for days rather than hours.

What’s particularly telling is the age of the vehicles involved.

Vans between four and nine years old appeared most often in the data, highlighting the financial risk once manufacturer warranties have ended and vehicles are kept in service longer.

Downtime hurts more than the bill

While the repair cost is painful, downtime is often the bigger issue.

Every day a van is off the road means missed jobs, rearranged schedules or the cost of hiring a replacement.

For small fleets running lean, there’s often very little slack.

WSG says the problem is being made worse by the growing complexity of modern vehicles.

While engines themselves are generally reliable, emissions systems and onboard electronics are becoming a major weak point.

Software faults, sensor failures and warning lights now account for a growing share of both cost and disruption.

It’s not always the big failures

Interestingly, it’s not just the headline-grabbing repairs that hurt. Diesel injectors and alternators together made up more than 8% of all claims, with average repair costs of several hundred pounds each.

Batteries and emissions components like NOx sensors and AdBlue injectors also appeared frequently.

On their own, these faults may seem manageable.

But over time, repeated “smaller” repairs quietly chip away at margins and cashflow.

What businesses should take from this

The key message is simple: running older vans carries increasing financial risk, even if they’ve been well maintained.

As vehicles age, repairs become more frequent, more complex and more expensive.

For small businesses, this makes forward planning more important than ever.

Understanding warranty cover, budgeting realistically for repairs, and knowing when a vehicle is becoming a liability rather than an asset can make a big difference.

At Cheshire Fleet Solutions, we can help businesses look at the full picture – not just the monthly cost of a van, but the long-term risk, downtime exposure and replacement timing.

If your vans are edging out of manufacturer warranty or you’re seeing repair bills creep up, it may be time for a conversation.

Sometimes the most cost-effective decision isn’t another repair – it’s a smarter replacement plan. If you would like a free audit of your current vehicle options, please feel free to drop us a line.