Warranty Solutions Group (WSG) has published its first Commercial Vehicle Market View Report.
Drawing on over 1,000 LCV claims paid by the company between January 2025 – December 2025, WSG analysed the top 10 highest-value claims for light commercial vehicles, revealing the most expensive claim topped £6,086 on a Mercedes Sprinter, with other high payouts linked to Nissan, Ford, Volkswagen, and Peugeot models.
The costliest claims were consistently linked to engines, turbochargers, diesel particulate filters (DPFs), and electronic control units (ECUs).
Vehicles aged four to nine years featured most prominently, underlining the financial risks operators face once manufacturer warranties expire.
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 report also identifies the most frequently occurring faults. Diesel injectors and alternators together accounted for over 8% of all claims, with average repair costs of £622 and £543 respectively.
Batteries represented nearly 3% of claims, while emissions-related components such as NOx sensors, AdBlue injectors, and DPFs were also prevalent.
