How much does it cost to replace an EV battery

How much does it cost to replace an EV battery?

How much does it cost to replace an EV battery?

We examine whether its a viable option to swap out the battery in an electric car if you ever need to

That flat and empty feeling

We all know the problem with batteries; they dont last forever.

Yknow, like when your mobile phone wont hold enough charge to last for a full day, or when a presentation drains your laptop and shuts down in the middle of a meeting.

Battery degradation is a frustrating counterpoint to the convenience of mobility and can virtually render portable devices useless. At which point, we either hand them down to the kids or donate them for recycling. And buy a new one.

That same disposable perception is one of the log jams in holding back a wider audience from adopting electric vehicles. Many potential EV buyers are afraid that the battery pack will be dead within a few years and the car will be completely worthless.

Indeed, the latest tranche of carsales EV buyer data shows a populace increasingly concerned about rising petrol prices and who will happily trade brands to get into an electric vehicle, but the fear of battery replacement costs in EVs remains a barrier to entry for many.

The fourth in a series of carsales research pieces that surveys current and prospective EV owners reveals that while the cost of buying a new EV is still a significant barrier, that level of concern has decreased since the last round of research six months ago.

However, its the issue of high-voltage batteries that still has people most concerned, with 72 per cent of respondents concerned about the cost of replacement.

No matter whether its your phone, laptop or electric car, replacing your battery is an alternative solution to disposal, but just how viable is that as an option to extend the life an EV? Lets find outEV battery replacement checklist

• Battery degradation is frustrating but real

• There's a multitude of reasons why EV batteries eventually fail

• Some manufacturers offer an eight-year battery warranty

• EV battery technology is getting smarter all the time

• The cost of battery replacement is expected to drop in the next few years

• There are things you can do to preserve the life of an EV battery

Why do batteries fail?

All rechargeable batteries will lose capacity over time. This is known as battery degradation.

Just a like a petrol tank, which can carry a finite amount of petrol, battery packs have a total energy capacity, which is measured in kiloWatt hours (kWh).

However, the chemical construction of the cathode an element inside each battery cell that essentially holds (and transfers) the charged electrons can break down over time, which reduces the amount of electricity a battery can store.

This can be caused by excessive heat when discharging electricity at high rates such as heavy acceleration or towing, when replenishing the battery using high-voltage charging infrastructure, or through damage via an impact.

In any case, its a little unfair to compare the battery in your phone to that in an electric vehicle.

Yes, they are very similar in their chemical structures, as most modern rechargeable battery packs use a lithium-ion compound. But the physical size of a mobile phone generally means the battery is just a single cell that throttles the flow of electricity (and therefore performance) to prevent overheating.

It also needs to be recharged more often (every day in most cases), which increases the number of charge cycles.

An EV battery is much larger and is subsequently made up of numerous cells, hence the term battery pack. This alone means that electric vehicles need to be recharged less frequently and can spread the storage (and flow) of electricity across all its cells, which reduces stress and prolongs the advent of degradation.

Some of the latest EVs have a battery pack that employs what are known as buffers, which are essentially sacrificial cells that are dedicated to degrade over time. This means the battery has a long-term useable capacity separate to its overall capacity that ensures the vehicle has a consistent driving range during its lifecycle.

On top of all that, cars, by their very nature, move through the air when in use which keeps the battery at more stable temperatures. Most EVs also now employ some form of additional cooling systems, either by using the air-conditioning or a dedicated refrigerant loop, to further prevent the battery from overheating.

They activate these systems when on the move and while recharging too, plus have a computer-controlled battery management system that alters the flow of electricity and limits the battery from charging beyond a certain ceiling to ensure it remains stable.

A longer battery life

With these factors combined, car-makers are able to offer greater peace of mind to EV consumers than other electronic device manufacturers.

As such, all EVs on sale in Australia are covered by at least an eight-year battery pack warranty, which guarantees against any construction defects as well as maintaining more than 70 per cent capacity over that period of time.High-voltage battery warranties for EVs sold in Australia:

• Audi eight years/160,000km

• BYD seven years/160,000km

• Hyundai eight years/160,000km

• Kia seven years/150,000km on HV battery

• Mercedes-Benz eight years/160,000km

• MG seven years/unlimited (commercial limited to 160,000km)

• MINI seven years/100,000km

• Nissan eight years/160,000km

• Polestar eight years/160,000km

• Tesla Model S eight years/240,000km

• Model X eight years/240,000km

• Model 3/Y rear wheel drive eight years/160,000km

• Model 3 Performance/Long Range eight years/192,000km

• Model Y Performance eight years/192,000km

• Volvo eight years/unlimited

The cost to replace a battery now

In all likelihood, you wont need to replace the battery in an EV for at least a decade.

And given the latest census results from the Australian Bureau of Statistics indicate the average age of vehicles across the country is 10.6 years, its unlikely you will ever need to replace your EV battery.

But in the event that you do, its not going to be a cheap exercise. The battery pack in an EV is the most expensive component in the vehicle, and the larger the battery the more it will cost to replace.

As a rule of thumb, global battery production costs have dropped to approximately $125/kWh, meaning for example that car-makers are buying a 100kWh battery pack for $12,500 before theyve even dropped it into the car.

Like any other replacement part, consumers will likely pay more than double that much from a dealer in order for the car-maker to recover overheads like logistics and storage while also making some retail margin.

Most brands with EVs on sale in Australia were reluctant to provide a recommended retail price for a replacement battery pack, citing the warranty provisions as peace of mind for consumers.

But carsales has managed to source a few examples from Hyundai for its Kona Electric and from Toyota for its range of hybrids.

The former has a 64kWh lithium-ion battery and it will cost $13,465.97 before fitment and labour costs to replace it.

Toyotas hybrid batteries are much smaller than those found in EVs and, before the latest Camry Hybrid arrived in August 2020, were cheaper Nickel Metal Hydride units. As such, they range from $2533.42 (including fitment) for the Prius to $3393.15 (including fitment) for the previous-generation Camry Hybrid.

Using those figures as a gauge, expect to pay between $12-20K for a replacement battery under 50kWh in vehicles such as the MG ZS EV, BMW i3, Nissan LEAF and MINI Cooper SE, and upwards of $50,000 in long-range prestige vehicles like the Porsche Taycan, Tesla Model S, Mercedes-Benz EQC and Audi e-tron.

The cost to replace a battery in a decade

While those are fairly eye-watering figures, the cost is expected to come down significantly over the next decade as production of electric cars increases.

Financial analysts predict the price of battery production will fall below $US100/kWh by 2025 a benchmark figure that will make the cost to produce EVs on par with conventional vehicles and to less than $US80/kWh by 2030.

What that means is battery replacement will become cheaper and a more viable option in the future.

With rapid advances in technology over the same timeframe, which should improve energy density and long-term battery health, it could mean a new battery will offer more driving range that could keep the current generation of EVs relevant for longer and justify the value of a battery replacement.

How to prevent battery degradation

Until then, there are ways to ensure the long-term health of your EV that could prevent ever needing to swap out the battery.

Firstly, the more often you charge a battery the more likely it is to degrade. So, unless youre commuting from Bendigo to Burwood and back each day, you dont need to plug it in every night.

Fewer charge cycles will reduce the likelihood of damage, so if possible only replenish the battery when it has less than 10 per cent capacity. Also, batteries will create heat when they are full, so limit its capacity when recharging to around 80 per cent.

They dont like holding onto a lot of electricity when stationary either, so if youre planning on leaving the EV in the garage for more than a few days then make sure the battery is around half full.

Also, monitor your charging methods and only use high-voltage DC public chargers when necessary. The high flow of electricity from these chargers naturally creates a lot of heat and can accelerate degradation.

Its best to use an AC home charging station (between 7-22kW) and utilise the cars on-board settings (or the car-makers app) to schedule overnight charging. This not only takes advantage of cheaper off-peak energy prices but allows the battery management system to properly pre-condition the battery and switch off the power flow when full.

Just as it is with a conventional car, understanding how to properly use and care for your vehicle no matter whether it has a battery pack in its floor or an engine under its bonnet will prolong its useable life.

Failing to do so can lead to the same result: leaving you with an expensive choice to make replace or recycle, or hand it down to the next generation.

Our team of independent expert car reviewers and journalistsMeet the team

How Much Does An Electric Car Battery Replacement Cost?

There are a lot of ways that electric cars can help you save money. Most importantly, you dont have to spend money on gasoline or diesel fuel ever again, but that doesnt negate the costs that you face for maintenance and repairs. One big concern is the price of EV batteries. So, how much does an electric car battery replacement cost?

In this guide, we cover the factors that affect EV battery replacement costs. We also look at some of the most popular EVs to give you a better idea of what you might spend.

At the end of this article, we give you some tips to prevent EV battery replacement and discuss whether you should replace the battery yourself to save money.

How Much Does An Electric Car Battery Replacement Cost?

A new electric car battery replacement can cost anywhere between $4,000 and $20,000, depending on the type of electric car you drive and the labor rate. However, you can find refurbished batteries for much less, even as low as $2,000, if theres one available for your vehicle.

There are many factors that affect the cost of EV battery replacement, so lets start with a quick look at those factors.

Factors Affecting Electric Car Battery Replacement Cost

1. Vehicle You Drive

As you will see in a moment, the price is dramatically different based on what vehicle you drive. You can replace the battery on a Chevy Volt for far less than you would spend with your Tesla.

However, just because the cost is lower doesnt make it a better deal. Depending on how long the battery lasts, you could actually spend less per kWh for one that lasts several more years.

2. Battery Materials

Most electric cars use lithium-ion batteries, but the amount of cells in each varies. They arent a single unit but can contain hundreds of cells. The more cells are included, the more capacity the battery has. We will talk more about the capacity in one second.

For this reason, electric car batteries dont have the same cost as a hybrid battery. In hybrid cars, the majority of the batteries are constructed from nickel-metal hydride instead.

3. Battery Capacity

Think first about a standard car battery. You pay more for larger car batteries than you would a smaller unit for a compact car. The same can be said about an EV battery.

If the electric car battery has a lot of cells, its going to have a larger capacity. This higher capacity design ensures a longer driving range, but it also means you will spend more for a replacement.

4. Warranty Protection

If your electric car battery fails prematurely, you can have the replacement covered by the warranty. Across the country, manufacturers are mandated by the federal government to supply a minimum of eight years and 100,000 miles of warranty protection.

If you buy an EV in California, the benefits are even greater. All EV and hybrid batteries must be covered for ten years and 150,000 miles.

RELATED: The Hidden Costs of Owning an Electric Car

Average EV Car Battery Replacement Cost by Model

To better understand the average replacement cost of electric car batteries, lets take a quick look at the average replacement cost of some popular electric car models.

1. BMW i3

Originally, the BMW i3 battery had a capacity of 22 kWh. You can purchase a new battery for around $16,000, which works out to about $727 per kWh.

However, there are also options to find these batteries on eBay. We found one selling for $3,300, listed as like-new. In this case, you would be paying $150 per kWh.

2. Chevy Bolt

Chevy Bolt EV battery replacements were quoted at about $16,250, with an additional $800 or so for labor. Because these batteries are 60 kWh, you are paying around $285 per kWh.

However, there has been a massive Chevy Bolt EV battery recall. Because of a defect, consumers can get a new battery for free, making it much more affordable to get a replacement.

3. Chevy Volt

If you are looking for a 16 kWh battery, you may spend about $4,000, which works out to around $240 per kWh. On the other hand, a 17.1 kWh battery might cost $6,000, which is closer to $350 per kWh.

If you want to save some money, you might be able to find a used battery on eBay for around $2,500 instead. That would put the per kWh cost at about $147 instead.

4. Ford Mustang Mach-E

The Mustang Mach-E is a newer model, so battery replacement isnt something most people are thinking about right now, which is good because its expensive. Even though these prices are high now, they will likely come down before any are actually needed.

In the meantime, Ford has a low-range battery (66 kWh) priced at $17,588 with a labor cost of $1,200. That equates to $285 per kWh. Theres also an 88 kWh battery listed for $25,319. Without labor, that means you would spend $288 per kWh.

5. Nissan Leaf

In 2020, the cost listed to replace a 24 kWh Leaf battery was $5,500. When this is broken down, you are spending about $229 per kWh.

If you are looking for a 40 kWh battery, you might spend a little more, around $6,000. Still, this breaks down to just $150 per kWh. Over the years, the price of these batteries has dropped dramatically. Just a decade ago, you could easily spend $10,000 or more.

6. Tesla Model 3

Once you get to the Tesla models, you are looking at a much higher battery replacement cost. Reports from 2020 reveal that a remanufactured battery for the Model 3 with a 75 kWh rating could cost $13,500 for the part and another $2,300 for the replacement. Thats $210 per kWh.

Again, these prices have come down significantly. Just a few years ago, they would have been even more, if you can believe it.

READ MORE: How Much Does it Cost to Replace a Tesla Battery?

7. Tesla Model S

Its not unusual to spend between $11,000 and $16,000 on a battery replacement for the Model S. With the 100 kWh battery, that cost can range anywhere from $110 to $160 per kWh.

However, a few years ago, owners were spending far more. In 2014, there were multiple reports of people spending $20,000 to $22,000 to have the batteries replaced.

READ MORE: How Much Does It Cost to Replace a Car Battery? (12 volt)

How to Avoid EV Battery Replacement

Considering the overwhelming cost of EV battery replacement, it makes sense to take every step possible to avoid it in the first place. We have a few tips that will keep your battery in its best condition, thereby prolonging the need for a replacement.

1. Avoid extremes. You dont want the battery levels going too low or too high.
2. Dont rely on DC Fast Charging. Its best to only use the fast charging stations when absolutely necessary.
3. Its best to charge the EV battery in smaller batches more frequently. You should avoid infrequently charging at larger capacities.
4. Before you charge the EV battery, try to ensure it is at room temperature. If you can charge in your garage, thats even better.
5. Keep the battery cooler during the summer months. Park in a garage or in the shade.
6. Avoid using more battery power than needed. The EV battery drains quickly when using air conditioning, heat and other accessories.
7. Be mindful of how you drive. If you can accelerate slower and avoid excessive speeds, the battery will last longer.
8. Swap out the tires for a more-efficient set. Make sure they are appropriate for the season and road conditions.

Aside from the tips weve given, the manufacturer probably offers even more advice. Check your owners manual and follow any recommendations given to make the battery last longer.

READ MORE: How Long Do Electric Car Batteries Last?

Should You Replace an EV Battery at Home?

If you are mechanically inclined and have changed a multitude of car batteries in the past, you may think this is a task you can tackle. However, without the right training and specialized equipment, its not advised to change an EV battery at home. You must understand how electric cars work and be able to diagnose the systems effectively.

Its also more difficult to find the schematics you will need to ensure everything is connected properly. One small mistake can fry the electrical system and you dont want to deal with that.

Theres also the aspect of physical danger. Because you are working with high voltage, its possible to get injured or even killed, which is why only trained professionals should replace EV batteries.

Considering how much money you will spend on a replacement EV battery, it doesnt make sense to take risks with it. The labor for installation isnt all that much more in the greater scheme of things, so leave this job to the experienced techs.

Is it worth it to replace the battery in an electric car?

Whether it is worth changing the battery in an electric car or not depends on how much your car is worth. The replacement cost for EV batteries can cost anywhere from $4,000 to $20,000, so if your car isnt worth that much money, it might not be worth it.

What happens if my electric car runs out of battery in the middle of nowhere?

If you are driving your electric car and it runs out of battery, it will stop completely, and you will have to call roadside assistance. Usually there is no other option than towing it to the nearest charging station. In some places, however, you can also find mobile charging stations.

How many batteries are in an electric car?

Electric cars usually have two different batteries. One for the 12 volt system and one large lithium battery for the high voltage system. However, a high-voltage lithium battery can consist of 2,000 plus individual lithium-ion cells

Replacing an electric car battery can cost you between $4,000 and $20,000, or even more depending on the car model. In the end, the cost of replacing an electric car battery can be very expensive and if you are not careful or prepared, it can cost you a lot of unexpected money.

Fortunately, many car manufacturers offer generous warranties for the EV battery and it will be replaced free of charge if it fails before the warranty period expires.

There are also various government incentives available to help with the cost of upgrading to an electric car. So if youre thinking about making the switch to an electric vehicle, be sure to do your research and find out what benefits may be available to you.

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Categories: Electric Vehicles, Estimator