What this checklist covers
High-voltage battery claims are among the most expensive warranty claims a dealer handles, and manufacturers check them closely. A claim is usually approved or rejected on its evidence: the battery health report, the diagnostic logs, and proof the failure is covered. This checklist makes sure that evidence is complete before the claim goes in.
The EV Battery Warranty Checklist is a 15-point scorecard for battery warranty eligibility, health reports, diagnostic logs, charging history, approval process, and claim documentation. Each criterion is scored from 1 to 5 on what the auditor sees on the day, and every gap goes into an action plan with an owner and a close date.
AutoSmart tip: EV battery warranty claims are among the highest-value and most technically complex claims in the warranty process. The two most common rejection reasons are insufficient diagnostic evidence (health report not attached or not formatted correctly) and absence of pre-authorisation. Establish a documented battery warranty claim workflow checklist separate from standard warranty procedures, reviewed by the warranty administrator before submission.
The checks
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Warranty eligibility and health report
- Is the battery warranty eligibility verified — covering the specific battery warranty period (often separate from the vehicle warranty) and any capacity retention threshold applicable to the claim?
- Is a battery health report (state of health, state of charge, cell balance, temperature history) generated using the OEM diagnostic tool and attached to every battery warranty claim?
- Does the battery health report output confirm that measured capacity has fallen below the OEM-defined warranty threshold — rather than the claim being based on customer perception of range reduction alone?
- Is the battery's VIN, serial number, and software version confirmed in the diagnostic report and cross-referenced to the vehicle's OEM records before claim submission?
Diagnostic logs and charging history
- Are diagnostic fault logs retrieved from the battery management system (BMS) and attached to the claim, providing OEM with visibility of any stored fault codes, charge events, or thermal anomalies?
- Is the vehicle's charging history reviewed as part of the assessment — checking for patterns such as sustained high-frequency DC fast charging, deep discharge events, or charging at extreme temperatures?
- Are BMS logs reviewed for any evidence of tampering, third-party software modification, or use outside the vehicle's specified operating parameters?
- Is the diagnostic log submission formatted per the OEM's warranty documentation requirement — not submitted as screenshots or informal exports — to avoid rejection on technical grounds?
Customer usage assessment and approval
- Is the customer's stated usage (charging habits, typical range, environmental conditions) documented as part of the claim, to provide context for the battery health data?
- Is pre-authorisation obtained from the OEM before any battery replacement is committed to the customer, where OEM policy requires pre- approval for battery warranty claims?
- Is the customer clearly informed of the claim outcome — including any aspect of battery degradation found to be outside warranty scope — before the vehicle is released?
Claim documentation and governance
- Is a complete battery warranty claim file retained, covering the eligibility check, health report, BMS log, customer usage record, OEM pre-approval, and invoice?
- Are replaced batteries tagged with the claim reference and retained per the OEM's parts retention policy, with no battery disposed of before OEM clearance is received?
- Is battery warranty claim rejection rate tracked, with rejected claims reviewed for recurring patterns in documentation gaps or assessment methodology?
- Is staff knowledge of battery warranty terms verified periodically — with service advisors and warranty administrators able to correctly describe the coverage threshold and documentation requirements without referring to a manual?
How to run it
How the scoring works
Before the visit, fill in the dealer or centre, the auditor, the date and the audit cycle. Then score each of the 15 checks from 1 to 5 on what you see on the day, not on what the site aims for, and add them up out of 75.
- 1Not in place
- 2Attempted
- 3Defined
- 4Managed
- 5Fully sustained
- Green60–75 · 80–100%Compliant. Keep the standard.
- Amber38–59 · 50–79%Improvement needed: a structured action plan within 30 days.
- Red0–37 · Below 50%Priority intervention, escalated to regional management.
Then close every gap
Each gap goes into the action plan tracker and moves through four stages until the auditor closes it.
- 1PendingOwner and close date set
- 2In progressWork under way, evidence gathered
- 3CompletedEvidence submitted for review
- 4ApprovedVerified and closed by the auditor
Questions about this checklist
Why are EV battery claims rejected?
Most often because the evidence is incomplete: no state-of-health report, missing logs, or no prior approval when the manufacturer requires it.
Who should check a battery claim?
The warranty administrator, with the EV technician confirming the diagnosis and evidence.
Is there a guide on EV readiness?
Yes: see our article on how OEMs audit EV readiness in dealer networks, linked below.
