According to the TÜV report 2026, the defect rate of trucks is high. (Photo: © udo72/123RF.com)
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1 October 2026
One in five commercial vehicles fails its mandatory vehicle inspection. Heavy trucks are particularly affected. The TÜV Commercial Vehicle Report 2026 reveals the biggest weaknesses.
An increasing number of commercial vehicles are exhibiting significant or dangerous defects during their mandatory vehicle inspections . According to the latest figures from the TÜV Commercial Vehicle Report 2026, one in five commercial vehicles (20,3 percent) failed the inspection during the observation period. The defect rate thus remains at a high level, having decreased by only 0,1 percentage points compared to the previous year. The report is based on the evaluation of approximately 2,4 million mandatory vehicle inspections, ranging from light commercial vehicles to heavy trucks, conducted by the TÜV Association member organizations in 2024 and 2025.
Heavy trucks over 18 tons have the highest defect rate at 21,8 percent . "The reluctance to purchase new heavy trucks in recent years is also having an impact," says Richard Goebelt , Head of Vehicle and Mobility at the TÜV Association. "The weak economy and the uncertainties surrounding the transition to new drive systems have contributed to vehicles remaining in service longer . This increases wear and tear, making maintenance and repairs more important." Defect rates increase with age, reaching 28,5 percent for ten-year-old vehicles. The average age of commercial vehicles is currently 8,9 years.
For light commercial vehicles up to 3,5 tons, the defect rate is 21,5 percent. Vehicles weighing between 3.5 and 7,5 tons show slightly better results, with a defect rate of 19,8 percent. Medium-duty trucks weighing between 7,5 and 18 tons perform best, with a defect rate of 16,3 percent.
For the first time, three electric vans in the under-3,5-ton class were included in the test . The Peugeot E-Expert achieved a defect rate of 8,4 percent in the one- to two-year-old age group , securing a respectable fifth place. In contrast, the Mercedes E-Vito fared significantly worse with 19,7 percent , primarily due to defects in the parking brake, drive shafts, and low-beam headlights. Bringing up the rear in the three- to four-year-old vehicle segment was the Streetscooter with a defect rate of 26,4 percent . "The results are not yet sufficient for an overall assessment of the technical reliability of electric vans," emphasizes Goebelt.
Operations management
Operations management
Operations management
The Maxus Deliver 9 from SAIC Motors is the first van from a Chinese manufacturer to be included in the TÜV report. Around a third (33,6 percent) of the one- to two-year-old vehicles failed the mandatory vehicle inspection , primarily due to safety-related defects in the braking system and frequent issues with the emissions test.
Oil leaks and oil spills increase with vehicle age. For example, 5,2 percent of five-year-old vehicles and eight percent of ten-year-old vehicles are found to have defects. Rear lighting defects affect 6,7 percent of vehicles after five years and 11,3 percent after ten years. The number of complaints regarding axle suspension rises from 1,5 percent for five-year-old commercial vehicles to five percent for ten-year-old vehicles.
According to the Federal Motor Transport Authority, the number of commercial vehicles in Germany increased by 1,8 percent to 3,9 million as of January 1, 2026. Compared to 2017, this represents a growth of 34 percent, driven primarily by light commercial vehicles and the increase in delivery and parcel traffic. The number of medium and heavy trucks is also continuing to rise. The shift towards electric vehicles is progressing: Between January and July 2026, the share of purely electric vehicles was 13 percent.
The electrification of commercial vehicles is gaining momentum. Manufacturers are expanding their model ranges, and government subsidy programs and the development of charging infrastructure are becoming increasingly important . However, charging infrastructure, particularly for heavy trucks, continues to pose an obstacle. Tax measures and toll exemptions also play a key role in operational planning.
The transformation encompasses not only the powertrain but also digitalization and driver assistance systems . According to the TÜV Association, the mandatory vehicle inspection must be adapted to allow for the structured evaluation of battery data and the reliable testing of driver assistance systems. "The European Union's Roadworthiness Package offers the opportunity to adapt the mandatory vehicle inspection to the requirements of electric drives, software controls, and automated driving functions," says Goebelt.
Note: The TÜV Commercial Vehicle Report 2026 is based on an analysis of approximately 2,4 million vehicle inspections conducted in 2024 and 2025. The results cover four weight classes, ranging from light commercial vehicles to heavy trucks over 18 tons.
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