HGV repair costs have soared by almost 12% in the last year, with a DAF cylinder head and camshaft being the single most expensive item at £10,800, according to new research.
Warranty Solutions Group (WSG) said DAF Trucks accounted for seven of the top 10 highest warranty claims, underlining the brand’s widespread use in UK fleets but also highlighting the potential cost when major components failed.
The remaining spots in the top ten analysis were filled by Scania (two claims) and Mercedes-Benz (one claim).
High ticket items included £9,000 for a DAF engine repair; WSG said the full repair cost was in excess of this but the claim limit was capped at £9,000.
A Scania turbocharger replacement was £9,383.
The research, based on a sample of 300 HGV warranty claims settled between May 2024 and April 2025 also found that the most common claims among eight-wheelers were brake pressure valves (£3,414.71) and engine control units (£3,415.29).
NOx sensors were the single most common failure across all types of HGV, making up 13.84% of all HGV claims and with an average repair cost of £780.45.
The main cause of failure was carbon build-up due to vehicle age and mileage.
Mark Bobbins, WSG head of commercial vehicle, said: “Over the past five years, the HGV sector has seen remarkable transformation, largely fuelled by advances in sustainability, safety, and automation. What was once a traditionally manual and mechanical space is now at the forefront of cutting-edge technology.
“Today’s trucks are smarter and safer than ever before. With the widespread adoption of advanced driver-assistance systems – such as lane-keeping aids, adaptive cruise control, and automated emergency braking – the risk of incidents is being reduced while driver wellbeing improves.
He added: “However, with this rapid evolution comes a challenge. The pressure to get vehicles back on the road quickly means there’s often little time to consider aftermarket options. Increasingly, we’re finding that operators default to main dealers for parts and repairs, simply to minimise downtime.”
