Ajusa understands how the electrification of the UK vehicle fleet is steadily progressing toward the targets set for 2030 and 2035. This shift is not only transforming mobility but also fundamentally redefining the aftermarket business model. In this new landscape, the traditional “replace rather than repair” culture surrounding Electric Drive Units (EDUs) is beginning to show clear signs of exhaustion, both economically and technically.
Today, the ability to repair electric motors is emerging as the new frontier for independent workshops and distributors, opening up high-value opportunities. In this context, Ajusa stands out as a key strategic partner, providing advanced technical solutions that turn complex failures into profitable and sustainable repairs.
A paradigm shift: Repair vs. Replace
The cost of fully replacing an EDU in common UK market models -such as the Nissan Leaf, VW ID.3, or Tesla Model 3, can range from £4,000 to £9,500 (excluding VAT and labour). In many cases, this exceeds the residual value of vehicles aged between five and seven years, often leading to premature scrappage.
However, field data reveals a very different reality: more than 70% of electric motor failures do not affect the high-voltage windings but rather mechanical or sealing components.
This opens the door to a more efficient technical approach: specialised repair using kits specifically designed for these systems.
The technical challenge: sealing and thermal management
Unlike internal combustion engines, electric motors integrate high-voltage electronics and conductive fluids within extremely compact spaces. This makes sealing systems a critical component.
- Dielectric Integrity and Moisture
The UK’s climate, characterised by high humidity and constant temperature fluctuations, creates particularly demanding conditions for sealing systems.
A simple leak can allow coolant (water-glycol) to enter the inverter or stator. Even a 0.05% moisture contamination in dielectric oil can reduce its electrical strength by up to 50%, leading to insulation faults that often result in incorrect diagnoses and full motor replacement.
- Chemical Compatibility and Corrosion
The heavy use of road salt during winter accelerates the degradation of external seals. Additionally, EV-specific coolants are more chemically aggressive than traditional fluids.
To address this, Ajusa has developed gaskets made from advanced compounds such as EPDM and FKM (Viton), capable of withstanding these conditions for over 150,000 miles, ensuring durability and reliability.
Applied engineering: Ajusa repair kits
Ajusa’s approach to the UK market is to simplify technical complexity with “all-in-one” solutions that ensure accurate repairs from the very first attempt.
The kits are developed for the most representative models in the UK market, including the Tesla Model 3 and Model Y, Nissan Leaf ZE1, Renault Zoe, and various Hyundai and Kia platforms.
Among its developments is the Coolant Bypass Kit, designed to resolve coolant leaks in the rotor -a common issue in high-performance vehicles- without the need to replace the entire motor.
The new-generation AjusEV sealant provides specific protection against humidity and extreme environmental conditions, particularly relevant for critical components such as the Power Control Unit (PCU) and battery housing.
The kits include all necessary components to disassemble, inspect, and reassemble the motor to original equipment specifications, eliminating uncertainty during the repair process.
Technical diagnostics: key to avoiding unnecessary replacements
Before recommending replacing an electric motor, it is essential to conduct a thorough diagnosis. Three tests are particularly relevant:
- Insulation Resistance (IR) Test: Detects whether coolant ingress has compromised insulation. Low values do not necessarily require replacement if the motor remains operational.
- Thermal Circuit Pressure Test: A drop greater than 0.05 bar/min indicates internal sealing failure.
- Weep Hole Inspection: The presence of fluid confirms failure of a dynamic seal.
These tests help identify low-cost interventions that prevent full replacements.
Training and support: A key differentiator
In the EV environment, technology is just as important as the knowledge required to apply it. For this reason, Ajusa complements its product offering with a comprehensive technical training ecosystem:
- Video tutorials accessible via QR codes included in the kits
- Detailed manuals with high-voltage safety protocols
- Step-by-step instructions for full motor assembly
A sustainable business opportunity
Electric motor repair is not only a technically viable alternative but also a strategic opportunity for the UK aftermarket. It enables:
- Reduced costs for the end customer
- Prevention of premature vehicle scrappage
- Increased labour profit margins compared to parts
- Positioning workshops as EV technology specialists
Ultimately, it is about giving electric vehicles a second life through sustainable solutions aligned with decarbonisation goals.
The future of electric vehicle maintenance in the UK lies in moving away from systematic replacement and embracing an advanced repair culture. With the right diagnostic tools and specific solutions such as Ajusa repair kits, workshops can turn a technological challenge into a competitive advantage.
Ajusa does not just supply components; it provides the knowledge, engineering, and support needed to lead this new era of the electric aftermarket.
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