Aftermarket companies are increasingly stepping up to the plate when it comes replacement drive components for EVs.

In Canada, electric vehicle sales have grown significantly over the last few years. According to data from the Canada Energy Regulator, more than 10% of all new vehicles sold in 2023 were zero emissions. While there are still debates as to whether the federal government’s highly ambitious targets for Zero Emissions vehicles to represent 100% of new car sales by 2035 will ever be achieved (and indeed, we have seen sales of battery electrics plateau in North America during 2024), the fact remains that these types of vehicles are becoming more frequent in aftermarket service bays.

Additional servicing

As they age, these EVs will require replacement components. Beyond the obvious, which includes tires, alignments and brake servicing, axles and drive systems will likely need attention, particularly as we see more EVs and hybrids used as taxis, ride-sharing vehicles and for food delivery services.

In response, the automotive aftermarket has been introducing more EV and hybrid specific replacement components. ZF Automotive Aftermarket has launched a range of new products, including 25 Electric Drive Axle Repair Kits for passenger cars and SUVs in the Canadian and U.S. markets. While in general terms, electric motors tend to wear less than comparable internal combustion engines in terms of moving parts, higher mileage (such as ride-share and taxi use), as well as contamination by dirt or corrosion of contact points as a result of seal failure, as well as moisture and salt (common in Canada, particularly due to winter driving conditions and humidity found in Eastern regions of the country), quality replacement parts are needed.

Available to order

In the case of ZF Automotive Aftermarket, Electric Axle Drive Repair Kits are available to order, and these kits have been specifically designed for ease of repair and installation. According to ZF they do not require removal of electric motors or drive axles from the vehicle, saving time on each Repair Order. Further aiding the process are the inclusion of all related parts and fasteners, allowing technicians with proper training (including certification on High Voltage systems), to perform a variety of tasks, ranging from replacing leaking coolant connections, to swapping out driveshafts, adjusting speed and temperature sensors and servicing parking lock systems.

“Repair shops are seeing more electric cars and need spare parts to service them. As one of the leading producers of electric drives worldwide, ZF is now making its products available to the independent aftermarket in our region,” says Mark Cali, Head of Independent Aftermarket, U.S. and Canada (USC). We are excited to launch these specially compiled kits for 25 repair scenarios with electric axle drive systems.”

Combined systems

At Schaeffler, electric drive and hybrid drive systems have also been a major focus in recent years. Both coaxial and parallel drive EV systems are available and Schaeffler offers a 2 in 1 electric axle system where the axle transmission is combined with an electric motor. Furthermore, Schaeffler has designed these units so they can also be combined with an electronic power unit to create an integrated 3 in 1 system. This has been further expanded via a 4 in 1 drive system, which integrates the electric motor, power electronics module and transmission into the EV axle drive. This arrangement is designed to make the axle drive system lighter and more compact (an important factor considering the weight of a typical EV on the market today). “This creates a highly integrated and compact completed system, which requires significantly less space than non-integrated solutions,” explains Dr. Jochen Schröder, Head of E-Mobility Business at Schaeffler.

Greater efficiency

By focusing on greater efficiency in the thermal management system, Schaeffler says it has developed a system that can go further on a single battery charge, another critical factor since range anxiety and limitation is still a primary concern among EV buyers and operators, whether private or commercial.

Besides the 3 in 1 and 4 in 1 systems, Schaeffler has also been developing electric beam axles for pickup trucks and at AAPEX, has showcased an all-electric Ford F-250 test vehicle, designed to demonstrate the potential of these electric drive systems, particularly in the North American marketplace where pickups are highly popular for both personal and commercial use.