Experiences with EV/PHEV Repairs and Battery Longevity

I’m curious about actual experiences with repairs on EVs and PHEVs, including any repair costs and at what mileage the problems occurred.

Also, is there any way to tell if a previous owner has worn down the battery by frequently using fast charging instead of slower, trickle charging?

I’m thinking of buying used to get the tax credit, so I’d like to know what common issues come up with EVs and PHEVs in the used market.

It’s hard to tell if a previous owner “abused” an EV battery, just like it’s hard to know if an engine was neglected in an ICE car unless there are visible problems. Some EVs have a battery health display, or you might be able to check it with a device connected to the OBD port.

For context: I have 28k miles on my EV with no problems so far. My wife’s PHEV (2014 Prius Plug-In) has around 215k miles, and while the battery capacity is down to about 80%, there haven’t been any major repairs.

Battery degradation usually just means reduced capacity, and that’s it. Electric powertrains, whether EV or hybrid, are pretty robust. There was a study on fast charging and its impact on batteries, and the results showed it doesn’t have a huge effect: EV Study Reveals Impacts of Fast Charging.

For PHEVs without battery conditioning, just be mindful of charging in extreme temperatures as it can lead to quicker capacity loss, though it’s unlikely to cause total battery failure.

@diallo
Thanks for the info!

Feels like a bit of a fishing expedition here.

EVs have standard maintenance issues like any car: tires, wipers, etc. You can find some cases of failures if you dig into forums, but you’re unlikely to see a ton of data. In short: yes, EVs can have problems, just like any other vehicle.

As for battery “abuse,” a well-designed EV should prevent this. The Nissan Leaf is an exception because it doesn’t have thermal management. Leaf prices reflect that issue, as most buyers know what they’re getting into, along with the limitation of CHADEMO charging.

@martin
Battery abuse can happen, especially if someone does ridesharing and only uses DC fast charging. There are cases, especially with Teslas, where batteries have degraded before 100k miles from heavy DC fast charging use.

@Howard
Fast charging alone doesn’t “destroy” EV batteries. The Leaf is a different story due to its lack of thermal management, leading to quicker wear in high temperatures. But in well-designed EVs, fast charging shouldn’t be a problem.

@martin
I don’t know much about CHADEMO or the specific issues with the Leaf, which is why I posted here.

In your opinion, what makes an EV “well-designed” for durability? Are there any standards for batteries, chargers, or connectors to look for when buying? I’d appreciate more info to help me understand these aspects better rather than assuming I’m “fishing” for negative takes. Just looking to learn.

@jabali
Check out the Kona EV forum. They discuss common issues, like oil changes for the gear reduction unit. Some EVs have rusted brake rotors from regenerative braking, and a workaround is to use neutral to engage the physical brakes more often. Some models handle this with software.

Look up battery types, management systems, and temperature limits online. For example, some batteries can’t charge well in extreme cold or heat.

Wikipedia is great for learning about battery management systems, and you can search for recalls to understand issues by model.

Try simpler words here if you’re new to EVs—no need for a dictionary. Quick searches can also answer a lot of your questions.

@jabali
Everyone starts somewhere. I got into EVs with a used 2014 Leaf and have since learned a lot. Now, my household has gone fully EV with both a Tesla and a 2023 Bolt we got for a good deal.

Not to assume, but your post sounded like you might be looking for common criticisms of EVs. EVs generally have fewer parts that can fail. For example, an electric motor has around 20 parts, while a gas engine has about 2,000.

Feel free to ask more specific questions—I’m happy to help!

AI often describes ICE longevity in terms of mileage, while EV battery degradation happens over both miles and years. Batteries do degrade, just differently.

Battery degradation involves:

  1. SEI (Solid Electrolyte Interface) growth, which can reduce lithium ions and capacity.
  2. Loss of active material on anode and cathode.
  3. Transition metal dissolution from cathode materials.

There are also other minor degradation factors like lithium plating, gas evolution, and mechanical stress. EV makers are aware of these and build battery management systems to protect against them, but the degradation does happen over time.

@Amelia
Edit: Replying here instead of the original comment I intended to reply to.

You’re listing a lot of battery degradation factors, which are accurate but don’t paint the full picture for EV longevity. EV makers design batteries with safeguards in mind to help prevent these issues from leading to serious damage.

For instance, the BMS (Battery Management System) will disconnect a battery at critical low levels and prevent overcharging. Many EVs also have cooling systems to keep batteries within a safe temperature range.

There’s real-world evidence of EV batteries lasting 300k miles or more before serious capacity loss. Often, other parts of the car wear out before the battery.

@sorphia
Those degradation pathways have been known since 2020 and were published online. In a recent interview, a battery expert mentioned there are over 30 such mechanisms, though not all were listed.

Older models, like early Tesla Model S cars, had design issues. Even newer Model 3s have seen some battery failures, though not all fail within 10 years. Meanwhile, my 14-year-old ICE Honda Accord still runs well because it’s not affected by calendar aging or battery wear.

I’m open to going EV but need to see longer battery lifespans. Hopefully, we’ll soon see batteries reliably lasting 16 years or more.