Costliest claims for van operators and most disruptive faults revealed

The top 10 most common light commercial vehicle (LCV) warranty claims have been revealed in new analysis from the Warranty Solutions Group (WSG).

The study, based on a sample of 1,000 extended warranty claims paid between July 2024 and June 2025, highlights the parts most likely to fail, the average cost of repair, and the makes and models involved in the most expensive warranty claims of the year.

The highest-value LCV warranty claim in 2025 was for a Mercedes-Benz Sprinter 316 CDI, with a significant engine-related claim valued at more than £6,000.

The Citroen Berlingo followed closely with nearly £5,000 in claims for various engine faults.

With multiple entries on the list, the Ford Transit also emerged as a recurrent concern for owners, appearing three times due to timing belt failures, turbocharger issues, and a full engine rebuild.

The data highlights that engine-related problems continue to be the costliest and most common cause of claims, often pushing warranty policies to their claim limits.

Components such as differentials, timing belts, and diesel particulate filters (DPFs) feature prominently, illustrating the complex and expensive nature of modern LCV repairs. Volkswagen’s Transporter models also made the list twice, with issues ranging from gearbox mechatronic failures to DPF replacements - costs that can easily catch owners off guard without robust protection in place.

Interestingly, claim values for the top 10 ranged from £2,500 to just over £6,000, with many hitting the cap imposed by warranty limits.

The Vauxhall Vivaro was another repeat offender, with two separate models making the list due to engine and DPF issues.

Mark Bobbins, head of commercial vehicle sales at WSG, says repair statistics highlight clear winners when it comes to LCV reliability.

“Repair data tells a compelling story about real-world reliability - and some LCV brands consistently hit fleets harder in the pocket when things go wrong,” he added.

“What we’re seeing is a growing pattern: emissions-related components like NOx sensors, EGR valves, and AdBlue injectors are not just expensive to replace, they’re also failing more often. This isn’t just a technical issue - it’s a financial one.

“With environmental regulations tightening and vehicle systems becoming more complex, the cost of non-maintenance is rising fast.

“Proactive servicing and strong warranty support are no longer optional, they’re essential for managing risk and maintaining fleet uptime.”

In the current economic climate, Bobbins says that one major repair can knock profitability off course.

“That’s why understanding which parts fail most, and planning accordingly, can make a measurable difference to a fleet’s bottom line,” he explained.

“Our live claims data helps operators make smarter decisions about vehicle selection, servicing, and protection.”

The WSG data also reveals the top 10 most common LCV warranty claims, with alternators topping the list, accounting for 5.35% of all claims and costing on average £506.78 per repair.

This is closely followed by NOx sensors (4.51%) and diesel injectors (3.67%), highlighting the high incidence of faults related to emissions systems and engine performance in commercial vehicles.

Bobbins continued: “Our findings also point to a significant financial impact when faults do occur, particularly with components such as the diesel particulate filter (DPF), which carries the highest average claim value at £1,303.75.

“Other high-cost claims include the dual mass flywheel (£943.48), turbocharger (£872.89), and EGR cooler (£850.98), suggesting that even lower-frequency faults can result in substantial out-of-pocket expenses for operators if not covered by warranty.

“These findings underline the importance of robust maintenance routines and comprehensive warranty coverage for LCV fleet operators.”

Fleet News has previously revealed the most reliable vans revealed according to the FN50 reliability index.

Volkswagen Commercial Vehicles was the most reliable manufacturer and the company’s Transporter was also recognised as the most reliable van.