The maintenance gap between ICE and BEV trucks

While the current political environment and emissions regulations rollbacks may have delayed the adoption of Class 8 battery electric trucks (BEV), the reality is that the performance and capabilities of BEV trucks are beginning to creep up on their internal combustion diesel truck (ICE) competitors. Most recently this was demonstrated in NACFE’s Run on Less – Messy Middle where we saw 500-mile range capable BEVs, with 600+ kwh charging capability, making real-world regional freight hauls.

So, assuming BEVs continue to improve in hauling performance, what other factors can we look at that set the two powertrains apart? Many would suggest that battery electric trucks have a significant advantage over ICE trucks as it relates to maintenance. Let’s explore why.

Maintaining ICE trucks

Class 8 ICE trucks are mechanical marvels, but that complexity comes at a cost. At the heart is the diesel engine, a symphony of pistons, valves, and injectors that demands regular attention. Oil changes are a staple, typically every 10,000 to 15,000 miles, to prevent sludge buildup and engine wear. For drayage trucks that idle frequently, this interval can halve, doubling the downtime. Then there's the fuel system: filters, pumps, and injectors need cleaning or replacement to avoid clogs from impurities in diesel.

The exhaust aftertreatment system—think diesel particulate filters (DPF) and selective catalytic reduction (SCR)—adds another layer of complexity. These components combat emissions but require periodic regeneration and fluid top-ups like diesel exhaust fluid (DEF). Failure here can trigger limp mode, stranding your rig. Transmissions, whether manual or automatic, involve fluid changes and clutch adjustments, while cooling systems demand radiator flushes to prevent overheating.

Brakes and suspension take a beating under heavy loads, with pads, rotors, and air lines needing frequent inspections. Overall, ICE trucks rack up maintenance every few thousand miles, leading to higher labor and parts costs. Data sourced through American Transportation Research Institute (ATRI), International Council on Clean Transportation (ICCT), and Argonne National Laboratory (ANL) triangulate diesel truck maintenance costs at around $0.25 per mile for Class 6 to 8 vehicles. That's not pocket change for a fleet logging millions of miles annually.

Maintaining battery electric trucks

Shift to a Class 8 battery electric truck, and the maintenance landscape simplifies dramatically. No engine means no oil changes, no spark plugs, no valve adjustments, and no fuel system woes. Electric motors have far fewer moving parts—often just one rotor—reducing wear and tear exponentially. This translates to longer intervals between service visits; some reports show BEVs logging 21 more days between maintenance than ICE equivalents.

Batteries are the star, but they're not maintenance-free. Cooling systems use specialized coolants to regulate temperature, preventing degradation. High-voltage components require safety checks by certified technicians, and software updates keep the powertrain optimized. Regenerative braking is a game-changer: it recaptures energy while easing the load on traditional brakes, extending pad and rotor life by up to double that of ICE trucks.

Tires, suspension, and cabin systems remain similar, but without the vibrations from a rumbling diesel, these might last longer too. Fluids for brakes and steering systems are still needed, but there's no engine oil or DEF. Maintenance for BEVs often focuses on inspections rather than replacements, making visits quicker. Per-mile costs? Around $0.17 for battery-electric trucks, a notable drop from diesel.

Differences and bottom-line impact

The core difference boils down to complexity. ICE trucks have thousands of parts prone to failure from heat, friction, and combustion, leading to 47% higher lifecycle maintenance costs than BEVs in some studies. BEVs eliminate many of these—no exhaust, no transmission in some designs—slashing routine upkeep. However, BEVs aren't immune: battery health monitoring and potential replacements (though warranties often cover up to five years) add unique costs. Downtime per visit might be longer for BEVs due to specialized repairs, but fewer visits overall balance this out.

A smoother road ahead?

As electrification accelerates, Class 8 BEVs promise a significant maintenance advantage—less frequent, less costly, and more predictable. While ICE trucks aren't vanishing soon, their upkeep burdens make BEVs an attractive pivot for cost-conscious operators. And, with more BEV infrastructure coming online, faster charging times, longer routes, and production costs projected to come down, Class 8 BEVs could be a viable alternative to traditional ICE trucks sooner than you think.