The shift to electric vehicles (EVs) is bringing significant changes to fleet maintenance patterns. Traditional diesel and gas-powered vehicles with internal combustion engines (ICE) have long-established maintenance schedules for both demand (or corrective) maintenance (DM) and preventive maintenance (PM). 

With EVs, however, the playbook is evolving.

Maintenance Visit Analysis: DMs and PMs

According to data and analysis from Utilimarc’s Electric Vehicle Consortium, electric pickups are logging fewer DMs than their ICE counterparts for model years 2022 through 2024 on an annual basis. 

Two factors play a part: First, EVs have fewer mechanical parts, and in the case of electric pickups, EV Consortium data shows that they are traveling fewer miles than their ICE counterparts, reducing the likelihood of a demand maintenance event. 

Preventive maintenance, however, is less about the technology and more about the mindset of the organization, according to Utilimarc. In general, across the EV Consortium member fleets, days between maintenance visits were 21 days longer in 2024 for EVs as compared to their ICE counterparts. 

Fleets with proactive service philosophies are keeping close tabs on their EVs, regardless of actual preventive maintenance needs. A fleet leader from Nashville Electric Service noted, “Our service manager pulls in the Lightnings once a month just to check them over.”

Alternatively, some members are adjusting schedules based on real-world usage and maintenance data.

Downtime: What’s the Real Story?

When it comes to downtime, EVs present a mixed bag for fleet operators. EV Consortium data shows that, on average, EV pickups experience about six hours more downtime within a month than ICE pickups, whereas EV and ICE small cars experience about the same amount of downtime each month. While EVs have fewer moving parts and should, in theory, be quicker to repair. 

Why the disparity? Consortium data reveals that the culprit isn’t mechanical failure; it’s logistics.

Some key challenges include:

• Internal vs. Outsourced Maintenance: Fleets that outsource EV repairs often experience longer wait times due to a lack of control and shuttling vehicles back and forth. Internal technicians, meanwhile, are still building EV proficiency, which contributes to slow turnaround when maintenance is performed in the fleet’s own garages.

• Learning Curve: As fleets continue to electrify, one theme is becoming clear: technician training isn’t just a nice-to-have, it’s critical and requires new tools, diagnostic processes, and training. Consortium member organizations have found that with in-sourced EV maintenance, a phased approach to training is effective, progressing from safety orientation to more advanced skills such as diagnostics and high-voltage servicing. This structure allows technicians to build competencies gradually and increase confidence. However, coordinating across multiple technician shifts, managing shop downtime, and securing budget for repeat training events all require logistical planning. 

EV vs. ICE Maintenance Costs

When evaluating maintenance costs, the story gets even more complex. Cost comparisons of EVs to ICE vehicles often require careful context, especially when it comes to vehicle age and usage patterns.

Key Data Points:

• The middle 50% of EV full-size pickups drive between 676 and 2,283 miles annually, whereas ICE pickups drive between 3,205 and 14,612 miles annually. Lower annual mileage on EVs can skew cost-per-mile calculations, making EVs look more expensive simply because the cost is spread over fewer miles. 

• In some cases, fleets may be over-maintaining EVs, scheduling unnecessary service visits out of an abundance of caution with unfamiliar technology.

The Takeaways for Fleet Managers

As technicians gain experience and competence working on electric vehicles, fleet managers will benefit from decreased downtime, stabilized maintenance intervals, and cost normalization.

Investing in internal EV training and carefully revisiting PM schedules can help mitigate some of today’s biggest challenges. 

About the Electric Vehicle Consortium 

The Electric Vehicle Consortium brings together fleet professionals, data analysts, and sustainability administrators to collaborate on solving the unique challenges of fleet electrification. Our members benefit from real-world data insights, collaborative research, and a strong peer network.  

Fleets or vendors interested in joining or sponsoring can contact evconsortium.org to learn more.