2026 EV Fault Rate Rises to 46.1%, Repair Costs 1.7x Higher Than ICE Vehicles

According to J.D. Power's 2026 China New Energy Vehicle (NEV) After-Sales Service Study, the incidence of vehicle problems among NEVs reached 46.1%, a 12% increase from 2025. The study noted that approximately 85% of user frustrations stemmed not from hardware failures but from owners’ difficulty in mastering complex smart features. Functions such as advanced driver-assistance systems (ADAS), charging management, and battery maintenance are highly integrated into the central touchscreen, featuring complicated operational logic, while customer support remains inadequate in responsiveness. Regarding accident repairs, the average repair cost for NEVs is 1.7 times higher than that for internal combustion engine (ICE) vehicles. Minor scratches on monocoque die-cast bodies often necessitate full component replacement; precision sensors like LiDAR units can each cost over RMB 10,000, and replacing an entire battery pack approaches half the vehicle’s original price. As automakers tightly control access to OEM parts and diagnostic tools—and given that most independent repair shops lack high-voltage servicing certifications—owners are largely forced to rely on brand-authorized 4S dealerships, which commonly adopt a “replace-only” policy instead of repairing components. Driven by rising repair costs, the average per-vehicle after-sales repair expense for NEVs increased by 23.3% year-over-year, intensifying insurers’ claims burden and resulting in generally higher premiums for NEVs compared to ICE vehicles of similar class. Following insurance claims, owner satisfaction drops significantly, primarily due to long parts waiting periods, inconsistent damage assessment standards, and cumbersome repair procedures.