The EV Inspection Gap: Why Traditional Shops Are Missing Critical Issues

As the number of electric vehicles (EVs) and hybrids on the road continues to rise, independent repair shops are facing a new challenge—properly inspecting and diagnosing electrified vehicles. While many technicians are comfortable servicing traditional internal combustion engine (ICE) vehicles, EVs require a different set of skills, tools, and safety procedures. The problem? Most shops aren’t adapting fast enough.
EVs don’t just replace an engine with a battery—they operate under completely different principles that impact everything from diagnostics to safety procedures. If your shop is treating EV inspections the same as traditional vehicle inspections, you could be missing critical issues, misdiagnosing faults, and even putting technicians at risk.
This article explores why the standard vehicle inspection process falls short for EVs, the most common mistakes shops make, and how you can upgrade your inspection process to stay ahead of the curve.
Why Treating EVs Like ICE Vehicles is a Costly Mistake
The fundamental issue is that EVs function differently than traditional gas-powered cars. Their drivetrains, energy storage systems, and braking systems are unique, requiring a different diagnostic mindset. However, many technicians are still relying on ICE-based diagnostic methods, which can lead to:

1. Misdiagnosed Issues – Many EV problems don’t trigger traditional error codes, making standard OBD-II scans insufficient.
2. Overlooked Battery Degradation – The battery is the most expensive component in an EV, yet many inspections fail to assess its long-term health.
3. Safety Hazards – High-voltage systems introduce risks that most shops aren’t fully prepared to handle.
4. Missed Business Opportunities – Customers need specialized EV inspections, and shops that offer them will stand out in the market.

Key Areas Where Traditional Shops Fall Short
1. Battery Health Assessments Are Overlooked
The battery pack is the heart of an EV, yet many technicians aren’t properly evaluating its condition. Unlike ICE vehicles, EVs don’t have as many moving parts that wear down over time, making battery health the single most important factor in an EV’s longevity.
🔹 The Issue: Many shops wait until a customer complains of range loss before checking the battery, but degradation happens gradually over time.
🔹 The Fix: Incorporate battery state-of-health (SOH) testing into routine inspections. Tools like the BATTSCAN battery tester can provide valuable insights into remaining capacity and expected lifespan.
2. Ignoring High-Voltage System Integrity
EVs operate on high-voltage (HV) electrical systems that require specialized inspection techniques.
🔹 The Issue: Many shops fail to perform insulation resistance tests or high-voltage cable integrity checks. These components can degrade over time, leading to shorts, performance losses, or even dangerous conditions.
🔹 The Fix: Train technicians in high-voltage diagnostics and safety protocols. Simple checks with insulation testers and thermal imaging cameras can prevent costly failures.
3. Regenerative Braking System Diagnostics Are Misunderstood
Regenerative braking allows EVs to recover energy when slowing down, but it also changes how brake wear and system diagnostics work.
🔹 The Issue: Technicians may misdiagnose a normal regen braking function as a fault or fail to assess the transition between regenerative and friction braking.
🔹 The Fix: Shops should incorporate regenerative braking tests into their inspection checklists and use scan tools to evaluate braking system behavior under different conditions.

How Shops Can Adapt and Stay Ahead
1. Offer Dedicated EV Inspections – Train technicians to conduct comprehensive electrified vehicle inspections that include battery health, HV system integrity, and regen braking assessments.
2. Invest in EV-Specific Tools – Standard OBD-II scanners don’t capture everything on EVs. Invest in battery analyzers, insulation testers, and thermal cameras to diagnose issues properly.
3. Get Proper EV Training – FutureTech Auto is hosting a FREE webinar on February 19, 2025, where we’ll cover everything you need to know about electrified vehicle inspections.
📅 Date: Wednesday, February 19, 2025
🕚 Time: 11:00 AM - 11:30 AM MST
💻 Register here: https://register.gotowebinar.com/register/4552835103636804960