Electric vehicles promise lower running costs and fewer moving parts, but fleet workshops, roadside support teams and remarketing experts are discovering a new set of operational challenges that councils and corporate fleets must plan for.
Speaking at the Fleet EV Expo for Local Government in November, specialists from Ultra Tune, CoolDrive and Autorola shared practical insights on servicing, diagnostics, roadside recovery and tyre management that are already reshaping fleet policies.
Servicing EVs: Skills, Certification and the Need for Triage
The industry consensus is clear: EVs require different workshop skills and safety protocols compared with internal combustion vehicles.
CoolDrive’s David Haley explained why fleets need a structured upskilling plan: “If you’re going to work on an EV, you need to be certified… The diagnostic work or the triage is always the hardest. The repair — that’s easy.”
CoolDrive built its EV support program around a strict order — training, safety, tools and then parts — to ensure technicians are safe and capable before touching high-voltage systems.
EV servicing is technically different but not necessarily more complex. Haley said: “EVs are a lot easier to repair, but they’re also a lot more dangerous.”
Ultra Tune is also preparing its network. Executive Sales Manager Anthony Curtin said around 20% of stores are now EV-qualified: “We’ve had quite a few more EVs come to our centres… we’ve actually pulled apart a lot of EVs and put them back together to see how to service them efficiently.”
For councils — many with mixed fleets and limited workshop capacity — the recommended approach is in-house triage and inspection, with repairs handled by certified EV specialists.
Roadside Support: Why EVs Get Stranded More Often in Car Parks
EV roadside incidents differ from ICE vehicles, especially where vehicles are parked for long periods or operated by multiple drivers.
Curtin said Ultra Tune’s call centre is receiving more calls from EV drivers stuck in multilevel or underground car parks: “People have gone on holidays or left the vehicle for an extended period… EVs still use power even when they’re not on.”
A flat auxiliary 12-volt battery — still used in EVs for locks, electronics and safety systems — creates additional complications: “If the actual auxiliary battery goes flat too, then you’re even in more trouble because you can’t even get into the vehicle.”
Some incidents are caused by driver unfamiliarity rather than mechanical faults: “We’ve helped a lot of people over the phone… people couldn’t even pull the charger out of the socket because they weren’t familiar with the vehicle.”
To support fleets, Ultra Tune is partnering with mobile EV charging providers to recover vehicles stuck in areas tow trucks cannot reach.
Tyres: The Most Underestimated Maintenance Cost in EV Fleets
If there is one area where fleets are already experiencing cost pressure, it’s tyres. EVs generally weigh more than their ICE equivalents and deliver instant torque — a combination that accelerates tyre wear.
Curtin highlighted how exposed most fleets are: “A lot of these EVs, 99% even, really don’t have a spare on them.”
Without a spare, a simple puncture can quickly turn into a costly tow, especially in remote areas or outside business hours.
Curtin recommended that Fleet Managers rethink their tyre strategy: “If you do have a fleet of EVs, invest in run-flat tyres. The cost compared to the ongoing tows is certainly beneficial.”
Tyre rotations are also more important for EVs due to uneven wear patterns: “Make sure those tyres are rotated at each service… the wear and tear of the instant torque will wear out the tyre faster.”
While some EV owners experience impressive brake life thanks to regenerative braking, tyres remain the first major consumable fleets need to budget for.
Driver Familiarity: The Hidden Factor Affecting Maintenance Costs
Another theme that emerged is the role of driver competence. Roadside teams are seeing basic operational errors — such as incorrect charging, forced removal of plugs or ignoring low charge warnings — that create avoidable downtime and additional fleet workload.
Curtin’s examples illustrate how EV unfamiliarity plays out in real operations: “We’ve had people that couldn’t even pull the charger out of the socket because they weren’t familiar with the vehicle.”
Training operators on vehicle basics, charging etiquette and emergency procedures can significantly reduce callouts.
Servicing Costs Can Be Low — If Fleets Use EVs Correctly
Haley shared his own fleet-relevant experience from six years of driving a plug-in hybrid: “Maintenance costs are virtually nothing… no brakes, no rotors, nothing like that.”
His experience reinforces a key point for fleet managers: EVs can deliver servicing cost savings, but only when supported by:
- Proper technician training
- Correct tyre management
- Clear driver instructions
- Preventative inspections
- Reliable charging access
The Bottom Line for Fleet Managers
EVs introduce new service intervals and new risks, but also new efficiencies. The panel’s collective advice is straightforward:
- Don’t treat EVs like ICE vehicles
- Invest early in staff training and workshop certification
- Prioritise tyre strategy and rotation
- Strengthen roadside support planning
- Give drivers clear, simple instructions
Fleets that get these fundamentals right will enjoy smoother EV integration, fewer unexpected costs and better availability across the life of the vehicle.
