The electrified future of automotive maintenance
For over two decades, I’ve been involved with servicing hybrid vehicles, and as of today, we’re well into servicing EVs as well. Depending on your location, you may not have had much exposure to these vehicles, so your interest in this article may vary. I’m here to share some of my perspective on what electrification means for service and what impact it might have on your business.
Background
Around 2004, my shop staff and I started attending classes covering hybrid vehicles. It was tough to find training on this subject since this new mode of propulsion was so new. Nevertheless, we started getting inquiries about performing services on Prius vehicles. Since we're located in Southern California, the Prius was becoming extremely popular.
EVs are transforming how we think about transportation. However, this shift also brings new challenges and opportunities, especially with service and diagnostics. Some newer manufacturers have reinvented the vehicle platform by building the vehicle from the ground up, bypassing some of the traditional methods from the past. What I am referring to here is the way the end user interacts with the vehicle. From entering the vehicle, starting the vehicle, and driving, many of these basic operations have been reimagined. If you’ve driven a Tesla, you know what I am referring to. (Figure 1)
The evolution of propulsion
For reference, EVs are not new. In fact, over 100 years ago, EVs were very prominent. From the 1890s to the 1910s, EVs were incredibly attractive to consumers. They were quieter, smoother, and easier to operate than their ICE rivals, no hand-cranking or complex gear-shifting required. EVs were especially popular in urban areas, where their limited range (30-50 miles) wasn’t a showstopper for short trips. By 1900, EVs accounted for about 38 percent of the U.S. car market, outpacing gasoline and steam cars.
Their dominance manifested from practical advantages: electricity had high availability in cities, and EVs appealed to upscale buyers, who valued the clean, low-friction experience. Companies like Baker Electric and Detroit Electric thrived, producing models that could hit speeds of 20-30 mph. (Figure 2)
But that dominance didn’t last. Battery tech was plagued with problems; lead-acid batteries were heavy, expensive, and slow to charge. Demand for longer ranges increased, and gasoline cars got cheaper and more reliable thanks to innovations like Ford’s Model T and its assembly line. By the 1920s, EVs couldn’t compete on price, and their appeal dwindled with an ever-increasing presence of gas stations popping up everywhere. And with the introduction of one of the most groundbreaking innovations, the electric starter, this made the gasoline vehicle more appealing than ever!
EVs faded to a niche by the 1930s, but their early lead showed what was possible when tech and demand aligned. It just took a century for batteries and infrastructure to catch back up.
Over the course of the century, internal combustion engines have dominated the automotive market. Service and repair mechanics and technicians have focused their skills on and around ignition, fuel, emissions, drivetrain, and electrical systems. Now, for EVs, they represent a significant technology shift in some of these systems. Instead of gasoline, they rely on electric motors to not only produce propulsion, but also support the refrigeration system, high-voltage batteries, and sophisticated software. This alternative propulsion system isn’t just a simple transition from the old formula, it’s an entirely new landscape. And with it comes a pressing need for specialized service and diagnostics tailored to the unique anatomy of EVs. (Figure 3)
Why EV service matters
Unlike traditional vehicles, EVs have fewer moving parts, which can mean less wear and tear on components like brakes or transmissions. However, this doesn’t make them maintenance-free. The heart of an EV is its battery pack. It requires careful monitoring to ensure longevity and performance. High-voltage systems, thermal management, and regenerative braking add layers of complexity that demand expertise beyond the scope of a typical mechanic’s garage. Additionally, EVs are 30-40 percent heavier than their ICE counterparts. Couple that with the instant torque being applied to the tires and suspension systems during acceleration and regeneration, and expect to see more frequent tire service, alignment, and suspension service. (Figure 4)
Charging infrastructure is another critical piece of the puzzle. As more drivers adopt EVs, service centers must be equipped to troubleshoot issues with onboard chargers, cables, and compatibility with public and private charging stations. I have personally performed service calls for difficulties with charging. Scan tools and some specialized equipment may be needed to address and identify trouble. Poor connections, hardware failures, and other faults can easily present a frustrating experience, making trained technicians invaluable.
Moreover, EVs are rolling computers. Over-the-air software updates can enhance performance or fix bugs, but when something goes wrong, it’s not always a wrench that’s needed; diagnostic tools and a deep understanding of system operation and data interpretation will be the assets needed to address issues efficiently. Technicians are a powerful breed, and those who continue to adapt will see success within the automotive service industry.
Diagnostics: The key to EV longevity
Diagnostics for EVs go far beyond what’s being shown to the consumer through the info display systems. Advanced tools are now essential to monitor battery health, assess motor efficiency, and pinpoint issues in real time. For instance, a technician might use onboard diagnostics or a third-party application to evaluate the state of health (SoH) of a battery pack. One of the common tests is electrochemical impedance spectroscopy (EIS) testing, which is a non-destructive method used to assess the health of battery storage systems. It involves applying a small alternating current (AC) signal across a range of frequencies to the battery during charging and measuring the resulting voltage response to find its impedance. EIS measures the battery's impedance, which reflects internal resistance, charge transfer, and diffusion processes, providing insights into battery degradation.
I was recently involved with performing battery health assessments through a company called ReJoule, located here in Southern California. They are an engineering firm working on several initiatives around battery health, including the repurposing of vehicle traction batteries into stationary power backup. Their processes were quite intriguing, and while I was able to work closely with their engineers, I learned quite a bit about this subject, however, I still have so much more to learn. Nevertheless, through the dozens of 24-hour HV DC charge cycles on multiple vehicles, a model was created, and this has led to a method for performing a battery health assessment on a battery pack that can be achieved in less than 30 minutes using their system. (Figures 5 & 6)
In addition to this type of testing, data logs can help reveal patterns that might predict future failures. Equipped with the right equipment and security access, a technician in the aftermarket can view high-resolution historic data to gain more insights on not only battery performance, but also other vehicle performance metrics.
One exciting development is the rise of predictive diagnostics. By leveraging artificial intelligence and machine learning, service providers can analyze data from thousands of EVs to anticipate problems before they occur. Imagine a dashboard alert warning a driver of a degrading battery cell weeks before it fails, or a service center proactively scheduling maintenance based on usage patterns. This isn’t science fiction — it’s the future of EV care, and it’s already here.
Training the next generation
The shift to alternative propulsion doesn’t just require new tools — it demands a new workforce. Automotive schools and certification programs are racing to update curricula, teaching technicians how to safely handle high-voltage systems and interpret diagnostic readouts. Organizations like the National Institute for Automotive Service Excellence (ASE) now offer EV-specific certifications, ensuring that service professionals are equipped for the electric age.
Let’s not forget about safety, this is a top priority. Working on an EV’s high-voltage components without proper training can be deadly, which is why specialized knowledge isn’t an option. From insulating gloves to lockout-tagout procedures, EV service is as much about protecting the technician as it is about fixing the vehicle. However, one must also be aware of the safety standards applied to vehicles in the U.S. Many safety provisions have been embedded in these systems, making it extremely difficult for one to hurt oneself. In fact, some vehicle manufacturers have no official provision for internal battery service. The battery is a replacement device with no pathway for internal service. However, as we are all aware, the aftermarket will always find a way. Bottom line, voltage can kill you, and you had better know what you are doing. As they say nowadays, "Fool around and find out!" (Figure 7)
The road ahead
The growth of EVs isn’t slowing down. Global sales soared past 10 million in 2022, and projections suggest that by 2035, electric models could dominate new vehicle markets. This momentum underscores the urgency of building a robust marketplace for EV service and diagnostics. Independent repair shops, dealerships, and even mobile technicians are adapting to meet the demand, offering everything from wheel alignments, battery swaps, drive unit replacement, and all that comes in between. (Figure 8)
Alternative propulsion is here, but as mentioned in the beginning, your geographic location may not see such vehicles for quite some time or at all. As EVs become the norm, the ability to service and diagnose these vehicles will determine how smoothly society transitions to this electrified future. Investing in the tools, training, and technology to support today could help you stay well ahead of the curve.
