For fleet operators and business owners, choosing the right commercial vehicles is essential to keeping vehicle fleets running efficiently. Vehicle maintenance, repair costs, and breakdown frequency all impact running costs, making reliability a key factor when selecting a compact van or larger pickup.

Data from WSG (Warranty Solutions Group) has provided valuable insights into which vans are the most (and least) reliable, based on real-world warranty claims. This report analyses the findings, highlighting common faults, the most expensive repairs, and how fleet management software can help businesses reduce downtime and unexpected costs.

Why Reliability Matters for Fleet Operators

A breakdown can be a major disruption for any business, affecting productivity, increasing costs, and in some cases, leading to lost contracts. Vans used for delivery services, construction, and trade work must remain operational to keep business running smoothly. Unexpected repairs not only affect running costs, but they can also impact customer service, especially for companies that rely on precise scheduling.

For fleet operators, reliability isn’t just about preventing breakdowns; it’s about ensuring long-term cost savings and efficiency. Many businesses are now investing in fleet management software to track vehicle usage, schedule maintenance, and predict potential failures before they occur. By using real-time diagnostics and predictive analytics, companies can reduce downtime and extend the lifespan of their vans.

Common Warranty Claims in Commercial Vehicles

The WSG study analysed over 1,000 warranty claims from vehicle fleets, revealing the most frequent issues affecting commercial vehicles. Among the most commonly reported faults were:

AdBlue system failures: Issues with AdBlue injectors, AdBlue pumps, and NOx sensors appeared frequently.

Turbocharger failures: Turbochargers were a leading cause of claims, with costs ranging from £800 to over £1,600.

Alternator and starter motor problems: Essential for vehicle functionality, these components were common reasons for breakdowns.

Diesel particulate filter (DPF) issues: DPFs are designed to reduce emissions but can become clogged over time, leading to costly replacements.

The data also revealed the most expensive warranty claims paid in 2024. The highest claim, a gearbox failure costing £5,500, while issues like DPF replacements, automatic transmission failures, and timing belt problems regularly exceeded £2,500 per repair.

The Least Reliable Vans Based on Claim Rate

While some models performed well, others were more prone to faults. The vans with the highest claim rates included:

Vauxhall Vivaro – 17.33%

Peugeot Boxer – 16.59%

Ford Transit – 15.82%

Volkswagen Transporter – 15.82%

Citroën Berlingo – 15.15%

Although these vans remain popular choices for businesses, the higher claim rates suggest that fleet managers should invest in preventative maintenance to reduce long-term repair costs. Using fleet management software can help track vehicle health, schedule routine servicing, and prevent costly breakdowns.

Strategies to Improve Van Reliability

For businesses that rely on commercial vehicles, taking a proactive approach to vehicle maintenance can significantly impact reliability. Routine maintenance can prevent small issues from turning into costly breakdowns; checking oil levels, brakes, and turbochargers regularly can extend the lifespan of a van.

Further to this, poor driving habits, such as excessive idling and harsh braking, can increase wear and tear so educating drivers on best practices can improve fuel efficiency and reduce repair costs. Using fleet management software, businesses can track van performance, mileage, and potential warning signs before they lead to failures.

Best Vans for Reliability

At the other end of the spectrum, some models had significantly lower claim rates, making them more dependable choices for businesses. Vans with the lowest claim rates included:

Ford Transit Connect

Toyota Proace

Peugeot Expert

Volkswagen Caddy

Renault Trafic

These models experienced fewer repairs, reducing running costs for fleet operators. However, one van outperformed the rest when it came to reliability.

The Most Reliable Van in the UK

After analysing the data, the van with the lowest claim rate, making it the most reliable van in the UK, is the Renault Master, with a claim rate of just 4.55%.

Despite some expensive repairs, such as gearbox replacements, the Renault Master had significantly fewer warranty claims than its competitors. For businesses that rely on commercial vehicles, this means lower vehicle maintenance costs and less unexpected downtime, ensuring more efficient operations.

With fleet operators facing increasing pressure to manage costs and keep vehicles on the road, choosing a reliable model like the Renault Master can make all the difference in maintaining an efficient fleet.

Whether you’re considering a Ford Transit Custom, Mercedes-Benz Sprinter, or Vauxhall Vivaro, reliability should be a key factor in your decision. While the Volkswagen Transporter and Peugeot Expert remain popular choices, the Renault Master stands out as the most reliable van, helping businesses keep their running costs low and their operations running smoothly.

By investing in the right commercial vehicles and implementing preventative maintenance strategies, businesses can ensure their vans stay on the road for longer, reducing unexpected repair costs and improving fleet efficiency.