1:19 pm, August 21, 2026
NOx sensors have emerged as the most common cause of warranty claims on used vans, with new data also revealing that the average repair is now costing almost £630.
Warranty Solutions Group (WSG) analysed more than 3,000 authorised light commercial vehicle warranty claims dating back to July 2021 to find out which components were most likely to land vans back in the workshop.
The results showed that NOx sensors were responsible for 5.3% of all claims, narrowly making them the most common issue ahead of alternators, which accounted for 5.1%.
Diesel injectors were not far behind at 4.5%, while turbochargers accounted for 3.3% of claims and diesel particulate filters (DPFs) made up another 2.7%.
Batteries, AdBlue injectors, starter motors, EGR valves, driveshafts and water pumps were also among the components appearing most frequently in WSG’s claims data.
Significantly, four of the 10 most common repairs were directly related to emissions-control systems, with the warranty provider saying the findings demonstrate how the increasing complexity of modern vans is beginning to change the type of repairs operators are facing.
While many of those individual faults are considerably less expensive than a major engine or gearbox failure, their frequency means the overall cost can quickly mount up.
Across all the LCV claims analysed, WSG found the average warranty repair bill stood at £628.83, including an average £127.72 spent on labour.
The average labour rate recorded across the claims was £60.47 an hour, although the most expensive individual repair identified in the data came to more than £6,000.
Engine, gearbox and turbocharger failures remained responsible for some of the largest individual bills, but WSG claims director Dennis Brett said operators should not assume that the most expensive failures are necessarily having the greatest impact on running costs.
He said: ‘One of the biggest misconceptions is that the highest repair bill represents the biggest reliability issue.
‘In reality, it’s often the faults that occur hundreds or even thousands of times across a vehicle parc that have the greatest commercial impact.
‘A £300 or £500 repair repeated across a fleet can ultimately cost operators far more than the occasional major engine failure.
‘By analysing more than 3,000 authorised warranty claims over five years, we’re able to identify patterns that simply aren’t visible from individual repairs.
‘Claims intelligence provides a unique insight into what’s really happening once vehicles are out in the field and how reliability is evolving as technology becomes more sophisticated.’
The findings suggest the make-up of van warranty claims is shifting away from being dominated by major mechanical failures, with emissions equipment and electronically controlled components now increasingly responsible for workshop visits.
For dealers and operators, that means relatively modest repairs to components such as NOx sensors, DPFs and AdBlue systems can become a significant cost when the same problems occur repeatedly across large numbers of vehicles.
Brett added: ‘The data shows that emissions-related systems and electronically controlled components are now among the most common reasons commercial vehicles require workshop attention.
‘These aren’t isolated incidents; they’re recurring issues that operators need to understand and plan for.
‘Modern vans are delivering higher levels of efficiency, lower emissions and greater connectivity than ever before, but that progress has also increased the complexity of vehicle maintenance.
‘Components such as NOx sensors, diesel particulate filters, AdBlue systems and electronic control units are becoming increasingly critical to vehicle performance.
‘That makes preventative maintenance, early diagnosis and access to specialist technical expertise more important than ever.
‘Operators that understand these trends will be in a much stronger position to reduce downtime, manage maintenance budgets and improve whole-life vehicle performance.’