Analysis from Warranty Solutions Group (WSG) showed that engine issues were the most common and expensive failures in vans in 2025.
WSG said that average van repairs ‘frequently’ approach £2,000 once diagnostics and emissions systems are involved.
NOx sensors were the most common of all failures in vans during 2025, accounting for 4.8% of all claims, with an average cost of £542.64.
This was followed by alternator faults, which made up 4.4% of all claims, costing £503.90 on average, while diesel injectors accounted for 3.54% of claims and cost £622.15 to rectify on average.
The most expensive of the top 10 most common van faults were diesel particulate filters (DPFs) and turbochargers, costing £1,180.09 and £948.09 respectively. DPFs had a claim rate of 3.47% while turbochargers had a claim rate of 1.67%.
Mark Bobbins, head of commercial vehicle sales at WSG, said: “The commercial vehicle sector is under significant pressure in 2025, with spiralling costs, ongoing parts shortages, and regulatory demands all impacting fleet performance.
“For many operators, downtime has become the single biggest challenge, every hour a van or truck is off the road directly affects productivity and profitability.
“With leaner fleets and older vehicles staying in service for longer, the maintenance ecosystem is being stretched like never before.
“We are also seeing the growing complexity of modern vehicles drive new types of failures. While mechanical systems remain strong, emissions technology and onboard electronics are presenting operators with software faults, sensor issues, and diagnostic challenges.
“These are problems that not only require costly repairs, but also specialist skills and equipment to resolve quickly and compliantly.”
The most expensive claim paid out on a van by WSG in 2025 was £6,086 on a Mercedes-Benz Sprinter, when a second-hand engine was fitted, along with oil and a filter.
A £5,089.38 claim on a Peugeot Boxer came second, for a heater fan motor, habitation and a heating system ignitor.
The third most expensive claim in 2025 was £4,950 for timing chains, a cylinder head, a water pump and a hydraulic lifter on a Citroën Berlingo.
A £3,548.98 claim for a turbocharger and throttle body on an LDV V80, along with a £3,424.92 claim for a gearbox and gearbox oil on a Ford Transit rounded out the top five.
Bobbins said: “Extended warranties and tailored protection packages are now a vital part of risk management for fleets.
“They provide reassurance by covering high-value components, supporting budget planning, and helping operators mitigate against unexpected costs.
“As electrification gathers pace, bespoke warranty solutions will be central to giving operators confidence in adopting new technology, while ensuring vehicles remain reliable and cost-effective throughout their working life.”
Mercedes-Benz Vans, Stellantis, Ford Pro and Maxus have been approached for comment.
