As electric vehicles enter fleet life cycles in greater numbers, the traditional metrics used to predict replacement timing and resale outcomes are shifting. At the Fleet EV Expo for Local Government last month, a panel of industry experts from Autorola, Ultra Tune and CoolDrive unpacked the emerging evidence around EV battery health — and the growing financial importance of formal battery testing.
Their message was clear: battery condition is rapidly becoming the number one determinant of EV residual values, and fleets must actively monitor it throughout the vehicle’s life.
EV Resale Values Are Under Pressure — and Battery Health Is Now Central
The used EV market is still maturing, but resale values are already showing downward pressure due to rapid technology improvements and aggressive new-vehicle price cuts.
Autorola’s Allan Fowler put it bluntly: “EVs are not trending as well as the ICE vehicle is… We’ve got a lot of new model vehicles coming to the market, and cars that are very, very sharply priced.”
Fleet operators feel this most acutely when disposing of early-generation EVs. With charging speeds, battery chemistry and range improving in each model cycle, used buyers naturally gravitate toward newer technology.
Fowler noted the impact on buyer preference: “Your first EV that you bought three years ago could charge to 80% in two hours. Your EV that you buy today would charge to 80% in 20 minutes… and you would pay accordingly.”
For fleets, that means battery health is no longer a hidden variable — it is an asset-value lever that can be measured, managed and monetised.
Battery Testing Is Emerging as a Core Fleet Maintenance Tool
With EV battery packs often representing 40–60% of the vehicle’s value, fleets cannot rely on range estimates alone. Independent testing is becoming a mainstream requirement, especially before disposal or life-cycle extension decisions.
Autorola’s Managing Director, Philip Browne, described how testing is reshaping fleet confidence: “Testing vehicles regularly is a good way of finding out whether you’re looking after the batteries well or not.”
Browne’s team has been conducting battery tests for three years across a wide range of EVs in Australia. The results have surprised many fleet managers.
“The batteries are performing, in most cases, much better than people ever expected… we’re not testing all that many vehicles that are less than about 90% [State of Health], and that’s up to vehicles up to 100,000 kilometres.”
Even high-mileage EVs are showing resilience: “We have done tests on some Teslas over 200,000 kilometres, and they have been in the 80 percents.”
For Fleet Managers, these insights are gold. A verified 90%+ battery health result can significantly bolster resale value and justify extending a vehicle’s life by one or two years when demand is soft.
Why Charging Behaviour Matters More Than Many Fleets Realise
Fleet battery deterioration is rarely caused by design faults — it’s usually caused by poor charging habits.
Browne highlighted common mistakes uncovered during testing: “They are charging to 100% every time they plug it in… constant charging over time does wear out the battery.”
He also warned about “just topping up” daily regardless of usage — a habit fleets might fall into when EVs return to depot each night.
“Constantly topping up a battery every day… is not so good.”
Philip Browne, Autorola
The result? Faster-than-expected degradation and poorer resale outcomes. Fleets that follow manufacturer guidance and teach drivers proper charging etiquette tend to see better long-term battery health — and higher second-hand values.
Battery Damage Is a Hidden Risk to Safety and Resale
Beyond gradual ageing, physical battery damage can dramatically reduce vehicle value and, in some cases, create safety risks.
Fowler emphasised the connection: “One of the biggest contributors to EV fires is a damaged EV battery. A normal, healthy battery is very unlikely to catch fire.”
Early detection through regular testing helps fleets trigger warranty repairs, maintain asset value, and avoid the steep resale penalties associated with battery replacements.
Why Battery Health Reports Will Soon Be Mandatory for Used EV Sales
Much like roadworthy certificates or odometer readings, battery health reports are poised to become standard in the used EV market.
Browne explained how testing protects both fleet owners and buyers: “The test will show if the battery is damaged in any way… it will allow you to have that battery fixed under warranty if it’s still under warranty.”
This transparency benefits council fleets especially, as they often operate under scrutiny regarding whole-of-life value and procurement decisions.
Fowler added that battery health directly influences what buyers will pay: “State of health will depend on how you were charging, discharging, how you were using the vehicle.”
In other words, battery care throughout the vehicle’s life impacts the financial outcome at disposal.
The Bottom Line: Fleets That Test Batteries Early and Often Will Win
The used EV market is evolving quickly, and battery testing is already separating high-value assets from low-value ones.
From the panel’s insights, the path forward is clear:
- Test batteries regularly, not just at end of lease
- Monitor charging behaviour and provide operator education
- Identify damage early to trigger warranty repairs
- Use battery health reports to support resale pricing
- Expect value variation as the market judges early EVs against newer technology
EV battery packs are proving more durable than many fleets assumed — but the fleets that measure, manage and document battery health will achieve the strongest financial outcomes when their EVs move into the second-hand market.
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