Busting the Maintenance Myth
Why “Low Maintenance” doesn’t mean “No Maintenance” for fleets.
Fleet professionals have heard the pitch: Electric vehicles (EVs) require little to no maintenance. It’s a compelling narrative, but not exactly true. As EV adoption accelerates across Canada, real-world experience is revealing a more nuanced truth: While EVs eliminate certain service items, they introduce new maintenance demands that fleets ignore at their peril.
That was the core message presented by Yves Racette, Director of Program Development for NAPA NexDrive. Speaking at the 2026 EV & Charging Expo in Toronto in April, Racette explained that EVs not only need maintenance, but in some cases they require maintenance that ICE vehicles don’t.
Counting the cost
Racette explained that repair bills for EVs can be significantly higher than for ICE vehicles, especially when issues escalate due to lack of preventive care. “A lot of times, electric light-duty fleet vehicles are not maintained properly,” he said. “Routine maintenance or preventive maintenance is not done because fleet managers were told that there’s no maintenance to be done.”
On the contrary, Racette explained, maintenance is a must, especially when you’re operating a fleet in Canada where humidity, snow, salt, and extreme temperatures are a daily reality.
Certain components, he added, must be properly maintained, simply because they’re critical to the proper functioning of an EV. Racette offered the example of an A/C compressor. In modern EVs, the A/C compressor is no longer just a comfort feature. It’s a must to regulate battery temperature, directly impacting performance, charging speed, and longevity. Ignore the compressor, and it could end up costing more than you might expect, he added.
“Fleet managers were told that there’s no maintenance to be done.”
- Yves Racette, Director, Program Development, NAPA NexDrive
Corrosion and fluids
Another key concern with EVs is corrosion. Battery enclosures, often constructed with aluminum parts, are particularly vulnerable. Visual inspections become essential. Catching corrosion early can mean the difference between a minor connector repair and a full battery pack replacement.
Preventive maintenance also extends to fluids—yes, even in EVs. They still need transmission oil and gear reduction oil, for example, so you’ll need to follow recommended service intervals and inspect or change fluids when required, Racette explained.
Despite some OEMs suggesting “lifetime” fluids, real-world experience says otherwise. Contaminated or degraded oil can lead to parts failures, overheating, and costly component damage. Regular inspection intervals—often around 60,000 km—are a prudent baseline, Racette noted.
Cooling systems present another layer of complexity. Today’s EVs use multiple coolant types, each with distinct chemical properties and compatibility requirements. “Mixing them can cause problems,” Racette said.
Rodent problems
Then there are the less obvious risks. Rodent damage, for instance, is increasingly common. Eco-friendly wire coatings can attract animals, and EVs, especially when charging overnight, provide a warm, sheltered environment. The result: chewed wiring, electrical faults, and unexpected downtime.
Even traditional systems behave differently in EVs. Braking systems, for example, see reduced use due to regenerative braking. While this extends pad life, it also increases the risk of corrosion and seizure if components aren’t regularly cleaned and lubricated. Similarly, suspension systems are under greater stress due to the added weight of battery packs, accelerating wear on bushings and joints.
Key takeaways
For fleet managers, the takeaway is clear: EVs demand a shift in maintenance strategy, not a reduction. According to Racette, preventive maintenance programs tailored to electrified vehicles can reduce overall costs by as much as 18–30% compared to reactive approaches, while also extending asset life and improving reliability.
As fleets continue their journey towards electrification, those who adapt their maintenance practices will see the greatest returns, not just in cost savings, but in uptime, safety, and long-term performance.
