Say goodbye to replacing the entire electric motor: ZF is preparing over 100 repair kits for various electric vehicles

When a bearing starts failing in an electric car, the problem can end up costing thousands of euros if the manufacturer decides to replace the entire propulsion unit. The German manufacturer ZF aims to change this situation with a new range of over 100 variants of repair kits for electric and hybrid propulsion systems. This proposal comes at a particularly interesting time, as the first electric cars sold in large numbers in Europe are beginning to accumulate years and mileage.

ZF’s strategy falls under the “Maintain-Repair-Replace” concept, meaning to maintain, repair, and replace in that order. The idea is quite simple: if a specific component of a power unit fails, there should be no need to replace the entire unit. A worn bearing, for example, doesn’t necessarily mean an electric motor that still works properly must be replaced as well.

For electric vehicles, ZF offers the Repair Kit RD, a set of components designed primarily for the bearings in the reducers of propulsion units. This component is responsible for reducing the rotational speed of the electric motor and increasing the torque delivered to the wheels. The bearings endure significant stress and may suffer premature wear due to lubrication issues, contamination, or misalignment. With these kits, the goal is to repair this specific component without having to replace the entire unit.

ZF’s offerings are not limited to electric vehicles either. The German manufacturer has developed various solutions for hybrid systems, including its well-known 8HP transmissions used by many manufacturers. Among these are the EM Kit, which combines rotor and stator sets for second-generation hybrid modules; the IN Kit, designed for fourth-generation inverters; and the ME Kit, which features refurbished fourth-generation mechatronic units for the transmission’s electronic and hydraulic control systems.

ZF claims to have manufactured over six million electric motors for various manufacturers, used in both electric vehicles and hybrid cars. This experience enables it to identify some of the most common recurring issues and develop specific solutions for the after-sales market. The company aims to share part of this knowledge with repair shops to facilitate faster repairs and prevent unnecessary replacement of components that are still functional.

The market for refurbished electric motors is already growing

ZF’s move comes at a time when there is already a market for refurbished components for electric cars. Models such as the Tesla Model S, Renault ZOE, first-generation Hyundai Kona Electric, and KIA Niro Electric already come with refurbished powertrain units. In some cases, these parts can be found at prices about 30% lower than those of new units offered through official channels.

The difference can be significant when dealing with a breakdown outside the warranty period. Replacing an entire powertrain unit can cost several thousand euros, while repairing only the faulty component allows the rest of the system to remain in use. For an electric vehicle fleet that is aging, having access to such alternatives becomes increasingly important.

ZF’s catalog for the after-sales market is quite extensive. The company offers around 2,400 transmission references, including approximately 600 mechatronic components. For electric vehicles, its catalog covers about 92% of the 20 most common models in Europe across various components, such as braking elements, steering systems, suspension parts, and transmission fluids, in addition to new solutions specific for propulsion systems.

That said, there is still important information that ZF has not made public. The company has not specified which exact models will be compatible with the new kits, how much each one will cost, or how many hours of work will be required to complete the repairs. As a result, it is still not possible to calculate how much money a owner can actually save compared to replacing the entire propulsion unit.

This point will be especially important once the kits reach repair shops and begin to be used on cars that are already out of warranty. Having a replacement part is one thing, but it’s quite another for the final cost of the repair to be sufficiently attractive compared to a refurbished or new unit.

The initiative also aligns with Europe’s growing focus on facilitating the right to repair and reducing industrial and electronic waste. ZF does not explicitly cite this regulation as the reason behind its strategy, but the direction the market is heading is clear. Repairing an electric motor instead of replacing an entire unit can reduce costs, extend the car’s lifespan, and prevent waste of components that are still in good condition.

For owners, this change could be particularly significant in the coming years. As the age of electric vehicle fleets increases, it will become increasingly important to have alternatives beyond going to the manufacturer to replace an entire unit and seeking used solutions. The introduction of specialized repair kits from a provider like ZF can help mature that market.