Common Reasons for EV Breakdowns

Electric vehicles (EVs) are growing in popularity with drivers around the world, and towing and recovery professionals are frequently called upon to assist stranded EV drivers. Although EVs are generally reliable, they have their own set of potential failure points that differ from traditional gas-powered cars. Understanding the most common reasons for EV breakdowns—and how to tow them safely—is essential for anyone in the towing industry.

At Collins Manufacturing, we specialize in building lightweight, high-performance towing dollies and equipment designed to handle all types of vehicles, including the newest electric models. Here’s a breakdown of what causes EVs to stall on the road, what makes EV towing unique, and why Collins equipment is the smart choice for any towing company servicing today’s vehicle landscape.

Common Reasons for EV Breakdowns on the Highway

1. Running Out of Charge (Range Anxiety) The most common cause of EV breakdowns is still a basic one: running out of battery. Although EV ranges are improving, drivers can still underestimate the distance they can travel—especially when high-speed driving, steep terrain, or extreme temperatures quickly deplete the battery. Unlike gas stations, EV charging stations are still sparse in many areas, making poor route planning or unexpected delays risky.

2. Battery Management System Failure An EV’s Battery Management System (BMS) monitors and controls the battery pack. If the BMS malfunctions or detects unsafe conditions—such as overheating—it can trigger a shutdown to protect the battery. This can leave the driver stranded even if there appears to be charge remaining.

3. Software Glitches Electric vehicles are heavily reliant on software. From the user interface to the drivetrain controls, a software malfunction can cause a host of issues, including the inability to start the vehicle or disengage the parking brake. These issues often require a diagnostic reset by a technician, not something that can be resolved roadside.

4. Charging Equipment Malfunctions Sometimes, it’s not the car—it’s the charger. Faulty public charging equipment, an incorrect voltage supply, or even a malfunctioning home charger can leave an EV owner with a partially charged battery or a vehicle that won’t accept a charge at all.

5. Flat Tires and Road Hazards EVs are typically heavier than gas-powered vehicles due to the weight of the battery pack. This added weight increases tire wear and can make EVs more susceptible to blowouts or tire-related issues. Unfortunately, many EVs come without a spare tire to reduce vehicle weight, making a flat tire a potential tow situation.

Towing Electric Vehicles: What You Need to Know

Towing an EV isn’t as straightforward as towing a traditional gas-powered car. EVs often have low ground clearance, high curb weights, and drive systems that don’t disengage in the same way as combustion-engine vehicles. Improper towing can lead to costly damage—especially to the battery, motor, or drivetrain.

Here are some towing best practices to follow:

1. Avoid Flat Towing or Typical Dolly Towing. Flat towing (where all four wheels remain on the ground) or using a tow dolly that keeps the EV’s back wheels on the road can be extremely damaging unless the manufacturer specifically permits it. That’s because the electric motors can be engaged by the wheels turning, potentially creating back-voltage that harms the vehicle’s electronics.

2. Use a  Flatbed Tow with our Collins Carrier Dolly. The safest way to tow an EV is with a flatbed where the entire vehicle is off the ground. The Collins Carrier Dolly easily fits each wheel of the EV for safe and easy transfer onto and off of a flatbed tow vehicle. This method prevents any drivetrain engagement and minimizes the risk of damage.

3. Watch for Locking Wheels or Electronic Brakes Some EVs use electric parking brakes that automatically engage when the vehicle is turned off. If the vehicle has no power due to a dead battery, the brakes can’t be released without special tools or manufacturer-specific procedures. Towing operators should be trained to identify and safely deal with these features. Because our Collins Carrier Dolly secures each wheel, they make moving an EV onto a flatbed easy even if the wheels are locked.

4. Secure Vehicles Carefully Because EVs are heavier than traditional cars, using equipment rated for heavy loads is critical. Lightweight or improperly rated equipment can bend, break, or fail under pressure—endangering both the tow operator and the vehicle.

Stay Prepared for the EV Future with Collins

As EV adoption grows, towing companies must adapt. That means training staff on how to safely handle electric vehicles and investing in equipment that supports the unique demands of EV towing. Understanding the common reasons for EV breakdowns and how to tow them safely is critical as the auto industry continues to evolve. No matter what type of vehicle is broken down, Collins Manufacturing is proud to be part of the solution, providing towers with the tools they need to work safely and effectively—now and in the future.

If you’re ready to equip your team with the best in electric vehicle towing equipment, explore our Carrier Dolly System, Tunnel Boxes, Mounts, and more at collinsdollies.com. We’re here to help you stay ahead of the curve, one tow at a time.