Battery replacement is the single biggest mid-life expense for electric mini trucks in India. For fleet operators, knowing the real cost of a battery pack, expected lifespan, warranty terms and cost-per-km impact is essential for calculating true TCO (Total Cost of Ownership).
This long-form guide gives brand-wise battery replacement cost, battery chemistry, official warranty, cost per km after replacement, and pack sizes for India’s popular 4-wheeler electric mini trucks:
- Tata Ace EV
- Mahindra eSupro Cargo (where available)
- Allcargo/EVage FR8
- Euler Turbo EV 1000
- Eicher electric LCVs (mini truck/3T segment)
- Ashok Leyland Electric Dost (expected model)
Why Battery Replacement Cost Matters
Battery is 40%–55% of the total EV cost. If a fleet runs 150–200 km daily, the battery may need replacement after warranty ends. Replacement price determines:
- Fleet operating margins
- Break-even point
- Long-term cost per km
- Resale value
- Maintenance budgeting
Understanding these numbers helps fleet owners plan accurate ROI for EV adoption.
Methodology Used for This Guide
To prepare brand-wise replacement cost, the following standard assumptions are used:
1. Battery cost per kWh in India (2025 estimate):
₹15,000 – ₹20,000 per kWh (cell + BMS + pack assembly)
2. Cost per km calculation:
Cost per km = Battery replacement price ÷ 200,000 km
(200,000 km is a standard remaining fleet life after replacement)
3. Warranty:
Official warranty details sourced from brand brochures and sales listings.
4. Chemistry:
Most mini trucks use LFP (Lithium Iron Phosphate) or Li-ion variants.
Brand-Wise Battery Replacement Cost Table (2025)
1. Tata Ace EV (1000 & Pro EV)
Tata Ace EV 1000
- Battery: 21.3 kWh
- Chemistry: LFP
- Official Battery Warranty: 7 years / 175,000 km
Estimated Replacement Cost:
21.3 × ₹15,000 = ₹3,19,500
21.3 × ₹20,000 = ₹4,26,000
Cost-per-km After Replacement:
₹1.60 – ₹2.13 per km
Tata Ace Pro EV
- Battery: 14.4 kWh
- Chemistry: LFP
- Battery Warranty: Up to 8 years / 175,000 km (varies by variant)
Estimated Replacement Cost:
14.4 × ₹15,000 = ₹2,16,000
14.4 × ₹20,000 = ₹2,88,000
Cost-per-km After Replacement:
₹1.08 – ₹1.44 per km
2. Euler Turbo EV 1000
- Battery: 15.36–16 kWh
- Chemistry: Lithium-ion
- Battery Warranty: 5 years / 150,000 km (extendable to 7 years / 200,000 km)
Estimated Replacement Cost:
15.36 × ₹15,000 = ₹2,30,400
15.36 × ₹20,000 = ₹3,07,200
Cost-per-km After Replacement:
₹1.15 – ₹1.54 per km
3. Allcargo / EVage FR8 Electric Truck
- Battery: 21.6 kWh
- Chemistry: Lithium-ion (high cycle life pack)
- Battery Warranty: Strong cycle life claims; confirm per variant
Estimated Replacement Cost:
21.6 × ₹15,000 = ₹3,24,000
21.6 × ₹20,000 = ₹4,32,000
Cost-per-km After Replacement:
₹1.62 – ₹2.16 per km
4. Mahindra eSupro Cargo (If in Market in Your Region)
- Battery: ~11.5 kWh (varies by year)
- Chemistry: Lithium-ion
- Warranty: Mahindra’s newer EVs have 7 years / 150,000 km. For eSupro, confirm with dealer.
Estimated Replacement Cost:
11.5 × ₹15,000 = ₹1,72,500
11.5 × ₹20,000 = ₹2,30,000
Cost-per-km After Replacement:
₹0.86 – ₹1.15 per km
5. Eicher Electric Trucks (Pro X / 2055 EV)
Eicher Pro X Mini Electric Truck
- Battery: 32–43 kWh (varies by variant)
- Warranty: 5 years / 200,000 km
Replacement Cost Example (32 kWh):
32 × ₹15,000 = ₹4,80,000
32 × ₹20,000 = ₹6,40,000
Cost-per-km After Replacement:
₹2.40 – ₹3.20 per km
Eicher Pro 2055 EV (3T Segment)
- Battery: 64.4 kWh
- Chemistry: Lithium-ion
- Warranty: 5 years / 200,000 km
Estimated Replacement Cost:
64.4 × ₹15,000 = ₹9,66,000
64.4 × ₹20,000 = ₹12,88,000
Cost-per-km After Replacement:
₹4.83 – ₹6.44 per km
6. Ashok Leyland Electric Dost (Expected Model)
Expected battery: 20–24 kWh (LFP) based on segment benchmarks
Expected warranty: 5–7 years depending on variant
Estimated Replacement Cost (20–24 kWh):
20 kWh = ₹3,00,000 – ₹4,00,000
24 kWh = ₹3,60,000 – ₹4,80,000
Cost-per-km Estimate:
₹1.50 – ₹2.40 per km
How to Calculate Battery Replacement Cost Yourself
Battery Replacement Cost = Battery kWh × ₹15,000 to ₹20,000
Cost-per-km = Replacement Cost ÷ 200,000 km
Example:
21.3 kWh × ₹15,000 = ₹3,19,500
Cost per km = ₹3,19,500 ÷ 200,000 = ₹1.60/km
Which EV Mini Truck Has the Cheapest Battery?
Here’s the ranking by lowest replacement cost:
- Mahindra eSupro Cargo (≈₹1.7–2.3 lakh)
- Euler Turbo EV 1000 (≈₹2.3–3.1 lakh)
- Tata Ace Pro EV (≈₹2.1–2.8 lakh)
- Tata Ace EV 1000 (≈₹3.1–4.2 lakh)
- EVage FR8 (≈₹3.2–4.3 lakh)
- Eicher Pro X / 2055 EV (₹4.8–12.8 lakh depending on size)
Tips to Reduce Battery Replacement Cost
- Prefer LFP batteries (longer cycle life, cheaper per kWh)
- Only charge up to 80–90% daily to extend cycle life
- Avoid fast charging more than necessary
- Park in shade; high heat accelerates degradation
- Negotiate pro-rata warranty in fleet contracts
- Use OEM-certified chargers
FAQs
1. How long does an EV truck battery last?
Most commercial EV batteries last 1,500–3,000 cycles, translating to 7–10 years for typical fleets.
2. Do OEMs replace modules or the full battery pack?
Some replace only modules; some do full pack swap. It depends on the OEM’s safety and warranty policy.
3. Is battery replacement covered under warranty?
If the State of Health (SOH) drops below the warranty threshold (usually 70%), OEM may replace under warranty.
4. Which battery chemistry is better?
LFP is better for commercial EVs due to:
- Higher cycle life
- Better heat stability
- Lower cost
5. Can local battery shops replace EV truck batteries?
Not recommended. OEM-certified battery packs ensure BMS compatibility, safety, and warranty protection.
