The rising cost of keeping HGVs on the road

The UK haulage sector is facing one of its most challenging operating environments in recent years. New HGV registrations fell by 10% during 2025, reflecting a difficult economic backdrop and causing many operators to extend vehicle replacement cycles.

Combined with ongoing driver shortages, inflationary pressures and rising maintenance costs, fleet operators are under increasing pressure to maximise vehicle uptime while controlling expenditure.

The scale of the challenge is reflected in Warranty Solutions Group’s own claims data. Across the eight major HGV manufacturers, average repair claims now stand at approximately £1,765 per incident, with many vehicles regularly generating repair bills in excess of £2,000.

More concerningly, some engine and turbocharger failures now exceed £9,000, while the most expensive claims recorded by WSG have surpassed £12,000.

Everyday faults such as NOx sensors, ECUs and AdBlue-related components continue to create a steady stream of repair costs that steadily erode fleet profitability.

These pressures are creating a perfect storm for operators. Inflation continues to drive up the cost of parts and labour, technician shortages are extending repair times, and increasingly sophisticated vehicle technology is making faults more complex and expensive to diagnose and repair.

Together, these factors are fundamentally changing the economics of keeping HGVs on the road.

The inflation effect

Inflation has affected every part of the commercial vehicle supply chain. Parts manufacturers continue to face higher production, energy and logistics costs, while workshops are dealing with rising overheads across staffing, premises and equipment.

These costs inevitably filter through to operators. Components that represented a manageable repair cost only a few years ago are now significantly more expensive to replace.

For fleets running dozens or even hundreds of vehicles, the cumulative impact can be substantial.

What makes the challenge particularly difficult is that many of these increases are outside the operator’s direct control. While businesses can improve fuel efficiency and optimise routes, they cannot easily mitigate rising parts prices or labour costs.

Labour shortages continue to drive repair costs

The shortage of qualified HGV technicians remains one of the most significant challenges facing the sector. Modern commercial vehicles require specialist diagnostic skills, particularly as emissions systems, electronic control units and advanced safety technologies become increasingly commonplace.

However, demand for skilled technicians continues to outstrip supply.

The result is twofold. Firstly, labour rates continue to rise as workshops compete for talent. Secondly, operators can face longer waiting times for repairs, extending vehicle downtime and creating further operational disruption.

For many businesses, the true cost of a repair is no longer limited to the workshop invoice. Lost utilisation, delayed deliveries and replacement vehicle costs often have a far greater impact on profitability than the repair itself.

Complexity comes at a cost

While modern HGVs are more efficient, safer and cleaner than ever before, they are also considerably more complex.

WSG’s claims data highlights how electronically controlled systems and emissions-related components are becoming increasingly prominent causes of repair claims.

NOx sensors account for more than 12% of HGV warranty claims, averaging £704 per repair, while ECU failures average more than £2,500.

Turbocharger issues cost operators almost £3,000 on average, while brake pressure valve repairs exceed £3,200.

What is often overlooked is the consequential cost that can arise from an initial component failure. A fault that begins with a relatively straightforward sensor, emissions or cooling system issue can quickly escalate if not identified and resolved promptly.

Secondary damage to connected components can significantly increase repair costs, turning what might have been a manageable repair into a far more expensive workshop visit.

For operators, this means the true financial impact of a failure is often much greater than the cost of the original component. Additional parts, labour time, diagnostic work and vehicle downtime can all compound the problem, highlighting the importance of early intervention and preventative maintenance strategies.

These are no longer isolated incidents. As trucks become more technologically advanced, fleets are increasingly exposed to faults involving specialist diagnostics, software integration and sophisticated component systems.

The challenge for operators is that complexity can increase both the likelihood and cost of repairs. A fault that might once have been identified and resolved quickly can now require specialist equipment, manufacturer-level diagnostics and highly skilled technicians.

Managing risk in a higher-cost environment

As operating costs continue to rise, fleet maintenance is becoming less about reacting to breakdowns and more about managing risk.

Operators are increasingly using telematics, service histories and warranty data to identify recurring failure patterns and intervene earlier.

Preventative maintenance strategies can help reduce the likelihood of major failures, minimise downtime and provide greater control over maintenance budgets.

Warranty protection is also playing a growing role in helping fleets manage financial exposure. As repair costs continue to increase, the value of predictable maintenance support becomes increasingly important for operators looking to protect margins.

Looking ahead

The pressures facing haulage operators show little sign of easing. Vehicle technology will continue to evolve, labour shortages are unlikely to disappear overnight and inflationary pressures remain a reality across the supply chain.

In this environment, controlling costs will require a more strategic approach than ever before. Operators that combine preventative maintenance, effective warranty protection and data-led decision-making will be better placed to manage risk, improve uptime and maintain profitability.

Keeping HGVs on the road has never been more challenging, but it has never been more important. The businesses that adapt to this new reality will be the ones best positioned to thrive in an increasingly demanding operating environment.

Dennis Brett is claims director at Warranty Solutions Group