How Much Do Major Car Repairs Cost in 2025?

Major car repairs typically run between $1,000 and $6,000, with high-end or complex jobs ranging from $10,000 to $20,000 or more depending on the vehicle and the system being repaired. Costs vary widely by make, model, region, labor rates, and whether parts are new, remanufactured, or used. Below is an up-to-date breakdown of what drivers can expect to pay for the most common big-ticket fixes, plus the factors that influence those prices and how to keep your bill in check.

What Counts as a “Major” Repair

In this context, “major” repairs are those that significantly affect drivability, safety, or vehicle value, often require many labor hours, specialized tools or programming, and typically exceed $1,000. These jobs include powertrain work (engine, transmission), hybrid/EV components, emissions equipment, and complex steering, suspension, braking, or electrical/ADAS repairs.

Typical Cost Ranges by System (USD, 2025)

Powertrain: Engine and Transmission

The powertrain is often the most expensive area to repair because it combines high parts cost with intensive labor and, in newer vehicles, software programming. The following list outlines common powertrain repairs and their current market ranges.

• Engine replacement (reman/new, mainstream): $4,000–$10,000; performance/luxury/turbo: $8,000–$20,000+
• Engine rebuild (where applicable): $3,500–$9,000
• Head gasket job: $1,800–$4,500 (higher for V6/V8 or cramped engine bays)
• Timing belt service (belt, tensioners, water pump): $500–$1,200
• Timing chain service (guides, tensioners): $1,200–$3,500
• Turbocharger replacement (single): $1,500–$3,500; twin-turbo: $3,000–$7,000
• Transmission replacement (automatic/CVT, mainstream): $3,000–$7,000; dual-clutch or luxury: $4,000–$15,000
• Transmission rebuild (where supported): $2,500–$6,000
• Clutch replacement (manual): $800–$2,500; add $400–$1,000 for dual-mass flywheel

Expect higher totals for luxury brands, AWD packaging, or vehicles requiring substantial disassembly. Using remanufactured or used components can lower costs but may affect warranty length.

Driveline, Suspension, Steering, and Brakes

These systems affect safety and ride quality. Costs scale with vehicle size, complexity (e.g., air suspension), and whether alignment or calibration is required after installation.

• Differential repair/replacement: $1,200–$3,500
• Axle/half-shaft replacement: $300–$800 each
• Wheel bearing hub: $250–$600 per corner (more for press-in or performance hubs)
• Shocks/struts (pair): $600–$1,800; full set: $1,200–$3,000
• Control arms/bushings (pair): $500–$2,000 depending on design
• Air suspension components: $2,000–$6,000 per axle if multiple bags/struts and compressor are involved
• Steering rack (hydraulic): $900–$2,500; electric power steering unit: $1,500–$3,000
• Brake overhaul (pads/rotors, one axle): $300–$800; all four corners: $600–$1,600; ABS module: $700–$1,500

After suspension or steering work, plan for alignment ($100–$250). Performance, off-road, and heavy-duty vehicles push costs up due to larger, specialized parts.

Exhaust and Emissions

Modern emissions systems are tightly integrated with engine management. Parts availability, especially in CARB states, and theft trends for catalytic converters influence price.

• Catalytic converter replacement: $900–$3,000; CARB-compliant: $1,600–$3,500
• Exhaust manifold with integrated cat (common on modern engines): $1,200–$3,500
• Oxygen sensor(s): $150–$500 each (often replaced with a catalytic converter theft repair)

Converter theft can add costs for O2 sensors, heat shields, and anti-theft plates. Insurance comprehensive coverage often applies, minus deductible.

Cooling and HVAC

Overheating risks engine damage, while HVAC issues affect comfort and safety (defrost). Electric water pumps and dual-zone systems raise complexity and cost.

• Radiator replacement: $400–$1,200
• Water pump: $350–$900 (electric pumps on some European brands: $700–$1,500)
• Heater core: $900–$2,000 (dashboard removal often required)
• A/C compressor: $900–$2,300; full A/C system rehab: $1,500–$4,000

Proper evacuation, recharge, and leak testing are essential with A/C work; using the correct refrigerant (e.g., R-1234yf) affects price.

Fuel and High-Pressure Systems

Direct injection and turbocharging have improved efficiency but added cost to fuel delivery. Access to in-tank components can also drive labor hours.

• In-tank fuel pump module: $400–$1,200
• High-pressure fuel pump (DI/turbo engines): $600–$2,000
• Fuel injector set (DI): $800–$2,500, plus potential carbon cleaning

On some models, injector coding/programming is required after replacement, adding time and scan-tool fees.

Electrical, Electronics, and ADAS

Modern vehicles rely on networked modules and sensors. Repairs can include both hardware and software, along with calibrations after body or glass work.

• Alternator: $400–$900; Starter: $350–$800
• Wiring harness diagnosis/repair: $300–$2,000+ depending on location and corrosion
• Windshield with ADAS camera calibration: $500–$1,700 (glass) + $200–$500 (calibration)
• Radar/ADAS sensor replacement and calibration: $600–$2,000+ per sensor
• Control module programming/updates: $100–$300 in labor/fees, sometimes more

Expect separate line items for diagnostics and calibrations; many systems require OEM-level scan tools and targets to meet specifications.

Hybrid and EV Components

Electrified vehicles reduce some maintenance but introduce high-voltage components with distinct cost profiles. Warranty coverage is often longer for these items.

• Hybrid battery pack (non-luxury): $1,500–$3,500 reman; $2,500–$5,500 new
• Hybrid inverter/DC-DC converter: $1,500–$4,000
• EV traction battery pack: $8,000–$20,000+ (model-dependent; some compact packs lower)
• Onboard charger or DC fast-charge components: $1,200–$4,000
• EV drive unit (motor/gearbox): $3,000–$9,000

Most hybrid/EV batteries carry 8yr/100k mile warranties (10yr/150k in many CARB states). Out-of-warranty packs vary widely by brand, capacity, and availability.

What Drives the Price

Repair totals reflect more than parts and time. The following factors commonly push costs up or down.

• Labor rate: roughly $90–$175/hr at independents; $140–$275/hr at dealerships; luxury/metro areas trend higher
• Parts choice: OEM vs aftermarket vs reman/used; CARB-compliant emissions parts cost more
• Packaging/complexity: AWD, turbocharging, tight engine bays increase labor hours
• Software needs: programming, coding, and ADAS calibrations add specialized time/fees
• Corrosion and age: rusted fasteners or seized components add labor
• Supply and brand: luxury, performance, and low-volume models have pricier parts
• Regional market conditions: urban areas with higher overhead see higher estimates

Line-item estimates let you see where money goes—helpful when comparing shops or deciding between new, reman, or used components.

When Insurance, Warranties, or Recalls Pay

Before authorizing a major repair, check coverage. The following programs often offset or eliminate costs.

• Factory powertrain warranties: commonly 5yr/60,000 miles (varies by brand)
• Federal emissions warranty: typically 8yr/80,000 miles for certain components (cats/ECU)
• Hybrid/EV battery warranty: usually 8yr/100,000 miles; 10yr/150,000 in many CARB states
• Safety recalls and service campaigns: free at dealerships, regardless of owner, within scope
• Comprehensive insurance: catalytic converter theft, vandalism, glass; subject to deductible
• Mechanical breakdown insurance/extended service contracts: coverage depends on plan terms and maintenance history

Always ask the shop to check for technical service bulletins (TSBs) and recalls tied to your VIN; these can change the repair path or reduce cost.

How to Get a Fair Quote—and Save

Smart shopping and clear communication can trim hundreds or thousands from a major repair, without sacrificing reliability or safety.

1. Request a written, line-item estimate with parts brands, quantities, labor hours, shop fees, and calibration/programming charges.
2. Ask for options: OEM vs aftermarket vs reman/used (with warranty length in writing).
3. Get a second opinion for repairs over $1,500 or involving engine/transmission replacement.
4. Verify TSBs, recalls, and warranty eligibility before paying out of pocket.
5. Prioritize safety-critical items (brakes, steering, tires, structural) if budgeting in phases.
6. Compare dealership vs independent specialists; look for ASE/Master techs and brand experience.
7. For ADAS/glass work, ensure proper calibration is included or scheduled.
8. Consider the vehicle’s value; if repair cost exceeds 50–75% of market value, evaluate selling or replacing.
9. Maintain proactively: fluids, timing belts, and cooling/ignition services avert catastrophic failures.

A transparent quote and informed choices on parts and shop type usually deliver the best value, while proactive maintenance avoids many “major” surprises.

Important Notes on Pricing

All prices are typical 2025 U.S. market ranges before tax and fees, for mainstream vehicles. Luxury, performance, and exotic models—and vehicles with severe rust or collision damage—can exceed these ranges, sometimes substantially.

Summary

Expect most major car repairs to cost $1,000–$6,000, with engine, transmission, and EV battery work often topping $10,000 on certain vehicles. Final price depends on labor rates, part choices, complexity, and required programming/calibration. Verify warranty or insurance coverage, compare detailed quotes, and weigh repair cost against vehicle value to make the most cost-effective decision.

What is considered a major repair on a car?

“Major vehicle repair” means any maintenance, repair or replacement not listed in the definition of “minor vehicle repair” in this subsection, including, but not limited to, the removal of engines, rebuilding of engines, repair of the internal components, repair or removal of differentials or axles, dismantling of …

What is the most expensive to fix on a car?

The most expensive car repair is typically an engine replacement, costing anywhere from $4,000 to over $10,000, with high-performance or luxury vehicle engines reaching even higher costs due to complex components and extensive labor. Another costly repair, particularly for electric and hybrid vehicles, is the EV battery replacement, which can cost over $17,000. 
Expensive Car Repairs by Category:

• Engine-Related Repairs
  • Engine Replacement/Rebuild: Often the most expensive repair due to the complexity and number of parts involved, a full engine replacement can range from $5,000 to $15,000 or more, especially for high-end vehicles. 
  • Head Gasket Replacement: While the part itself is relatively inexpensive, the extensive labor required to access it makes this a costly repair, sometimes exceeding $1,500-$2,500. 
  • Timing Belt Replacement: Similar to head gasket repair, the high labor costs for dismantling the engine to replace a timing belt contribute to its expense. 
• Electric and Hybrid Vehicle Repairs
  • EV Battery Replacement: The high-voltage battery is a critical and costly component of electric and hybrid cars. The cost for a replacement battery can range from about $4,500 to over $17,600. 
  • Hybrid Inverter Assembly Replacement: A hybrid inverter, which regulates electricity, can be an expensive part to replace if it fails, potentially costing $4,000 to $8,000. 
• Other Major Repairs
  • Transmission Replacement: Replacing a transmission is a significant expense, often ranging from $3,000 to $9,000. 
  • Catalytic Converter Replacement: The cost of this repair is often driven up by the value of the precious metals within the converter, making it a target for theft, notes Braman Miami. 

At what point is it too expensive to repair a car?

Repair Costs: If the cost of repairs exceeds the car’s current market value, it may not be worth fixing. A common guideline is the “50% rule,” where if repairs exceed 50% of the car’s value, consider replacing it.

What is the 30-60-90 rule for cars?

The 30-60-90 rule for cars is a recommended maintenance schedule for vehicles, with major service intervals and inspections occurring at 30,000, 60,000, and 90,000 miles. These services are crucial for checking and servicing key components like the engine, brakes, belts, and fluids, and following them helps prevent costly repairs, maintain optimal performance, and extend the vehicle’s lifespan. 
What the 30-60-90 Rule Entails:

• 30,000 Miles: Opens in new tabThis is a vehicle’s first major service milestone. Services include changing the oil and oil filter, replacing the engine air filter, and rotating the tires for even wear. 
• 60,000 Miles: Opens in new tabThis milestone requires an examination of components that often need more attention by this point, such as the battery, brakes, and spark plugs. Other services include inspecting the serpentine belt and potentially replacing it. 
• 90,000 Miles: Opens in new tabThe 90,000-mile service includes a thorough inspection of tires, replacing necessary fluids like the cooling and steering systems, and checking or replacing the timing belt and brakes. 

Why It’s Important:

• Prevents Major Breakdowns: Following this schedule helps to identify and address minor issues before they become costly repairs or lead to a complete breakdown. 
• Maintains Performance: Regular maintenance ensures your engine receives the proper airflow and lubrication, leading to better performance and improved fuel efficiency. 
• Extends Vehicle Life: Adhering to the 30-60-90 maintenance milestones is essential for the long-term health and functional lifespan of your vehicle. 
• Ensures Safety: Worn brakes, suspension components, or other critical systems can compromise your safety on the road. Regular maintenance ensures these systems are in good working order.