NOx sensors and turbochargers are the most common HGV faults, according to claims analysis conducted by Warranty Solutions Group (WSG).
Over the past five years, NOx sensor faults have accounted for 14.08% of all HGV warranty claims paid out by WSG, with repair costs averaging £726.16 including VAT.
Turbochargers accounted for 4.85% of claims, although average claim costs were significantly higher, at £3,050.17.
ECU faults accounted for 4.22% of claims, ahead of AdBlue pumps (2.97%) and water pumps (2.13%).
Of the top 15 most common warranty claims, the most expensive repairs were for camshafts, averaging £4,450.90.
Camshaft faults were sixth-most-common, accounting for 2.05% of all claims.
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The average HGV warranty claim cost £1,558.50.
At £15,000, the most expensive HGV warranty claim was for an engine replacement, although this was capped by the claim limit.
Other high-value HGV warranty claims included a turbocharger replacement (£12,137.66), and an engine and camshaft replacement (£10,800).
Dennis Brett, claims director at WSG, 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 repeatedly across thousands of vehicles that have the greatest commercial impact.
“A repair costing several hundred pounds but occurring time and time again across a fleet can ultimately have a greater financial impact than the occasional catastrophic engine failure.
“By analysing almost 2,500 authorised HGV warranty claims over five years, we’re able to identify patterns that simply aren’t visible from individual repairs.
“Claims intelligence gives us a unique understanding of how truck reliability is evolving and where operators are facing the greatest maintenance challenges.
“The data shows that the profile of HGV repairs is changing. Modern trucks are delivering greater efficiency, lower emissions and improved connectivity than ever before, but that progress has also increased the complexity of vehicle maintenance.
“Components such as NOx sensors, AdBlue systems, engine ECUs and advanced emissions technology are now among the most common reasons heavy commercial vehicles require workshop attention.
“At the same time, when major components such as engines, turbochargers, camshafts or crankshafts fail, repair costs can quickly run into many thousands of pounds.
“For operators already working with tight margins, every day a truck is off the road represents lost productivity, delayed deliveries and increased operating costs.
“Claims intelligence allows us to look beyond individual repairs and understand what is happening across the wider truck market. Every warranty claim tells a story, but thousands of warranty claims reveal meaningful trends.
“Those insights help operators identify recurring issues earlier, improve maintenance planning and make better-informed decisions around whole-life vehicle costs.
“As fleets continue to operate vehicles for longer while managing increasingly sophisticated technology, understanding real-world reliability has never been more important.
“Businesses that use claims intelligence to support preventative maintenance strategies will be far better placed to reduce downtime, improve vehicle availability and maximise operational efficiency.”
