• New research reveals which vans cost drivers the most to fix, analysing average repair bills for engines, suspension, brakes and other key systems, while also ranking each model’s reliability. 
• Nissan NV200 and Fiat Doblo Cargo rank as the most cost-efficient, combining low average repair costs with high reliability scores. 
• At the other end of the scale, the Ford Tourneo Custom and Volkswagen Caravelle face steeper repair bills and poorer reliability ratings.

Van ownership isn’t just about the upfront price tag; it’s also about the long-term costs of keeping your vehicle on the road. Costly engine failures or gearbox repairs running into the thousands can turn owning a van into a financial headache.

Planning ahead pays off, whether by setting aside a repair savings pot or choosing a van with proven reliability. To help drivers make informed choices, the temporary van insurance experts at Tempcover have launched a new Van Repair Index, highlighting the UK’s most and least expensive vans to fix.

The study examined over 27 popular UK van models, from panel to passenger vans, combining independent data on reliability, average repair bills, and claim rates for major components like engines and gearboxes to show how repair costs vary across different makes and models.

Compact Vans Top the Ranking

The Nissan NV200 takes the top spot with an impressive Index Score of 89.9, thanks to its high reliability score of 9.1 and low average repair bill of £303.94. Compact, reliable, and affordable to fix when problems occur, it shows how smaller vans can help keep repair costs down.

Close behind is the Fiat Doblo Cargo, another compact commercial van, scoring 89.2 with the lowest average repair costs of £282.78. The Peugeot Partner follows with an index score of 63.7 and slightly higher average repair costs of £490.08, while the Mercedes Vito and Citroën Dispatch complete the top five.

Top 10 Best Performing Vans 

Rank	Van Make & Model	Avg Repair Cost (£)	Reliability Score	Overall Index
1	Nissan NV200	£303.94	9.1	89.9
2	Fiat Doblo Cargo	£282.78	8.9	89.2
3	Peugeot Partner	£490.08	7.8	63.7
4	Mercedes Vito	£436.78	7.1	61.8
5	Citroën Dispatch	£576.14	8	60.5
6	Vauxhall Combo	£683.56	8.5	57.2
7	Citroën Berlingo	£569.71	7.3	54.4
8	Peugeot Expert	£561.59	7.2	54
9	Volkswagen Caddy	£557.19	7.1	53.1
10	Volkswagen Caddy Maxi	£468.07	5.3	46.2

Ford and Volkswagen Models Dominate the Worst-Performing List

The Ford Tourneo Custom and Volkswagen Caravelle rank among the most expensive vans to repair in the UK. The Tourneo tops the list with an average repair cost of £1,746.80, followed by the Caravelle at £1,408.59, with both vehicles also scoring the lowest reliability rating of 1.

Well known brands such as Volkswagen and Ford fared poorly overall, with both having 3 models each appearing in the bottom 10.

Top 10 Worst-Performing Vans

Rank	Van Make & Model	Avg Repair Cost (£)	Reliability Score	Overall Index
1	Ford Tourneo Custom	£1,746.80	1	0.8
2	Volkswagen Caravelle	£1,408.59	1	2.3
3	Citroën Relay	£1,262.08	1	3.4
4	Volkswagen Crafter	£1,133.43	1.4	7.4
5	Hyundai I800	£970.99	1.1	9.2
6	Ford Transit Custom	£1,361.88	2.7	10.7
7	Peugeot Boxer	£1,092.82	2.1	10.9
8	Volkswagen Transporter	£1,411.03	3.3	12
9	Renault Trafic	£939.20	1.8	12.2
10	Ford Transit	£1,069.87	3.6	16.2

*The tables provide a full breakdown of the top 10 best and worst-performing vans based on their overall Index, a combined measure of reliability and repair cost-effectiveness. A higher index score indicates a more reliable and cost-effective vehicle.

Engine and gearbox problems drive the highest repair costs. For example, the Ford Transit Connect has the highest average engine repair bill at £3,614.93, alongside gearbox repairs averaging £1,066.06.

Compact Vans Lead the Way for Low Repair Costs

The study also revealed trends by van size. Compact models, such as the Nissan NV200 and Fiat Doblo Cargo, consistently rank among the best performers, offering low average repair costs alongside strong reliability. While some larger vans, like the Mercedes Vito and Citroën Dispatch, scored reasonably well, the data suggests that, in general, smaller vans are cheaper to keep on the road. 

Claire Wills-Mckissick, an expert in temporary van insurance at Tempcover, adds:

“Van repairs can be both costly and disruptive, often leaving drivers without the vehicle they rely on for work. That’s where short-term insurance becomes a vital safety net.

“With Tempcover’s flexible short-term van cover, you can get back on the road quickly in a borrowed or replacement vehicle while yours is in the garage. Whether it’s keeping a business moving or ensuring you can still take on jobs, temporary insurance provides the flexibility to stay mobile without being tied to a long-term policy, minimising downtime and keeping your work on track.”