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Cost of Repair: When shops need to tell customers the bad news

When high-mileage, older vehicles arrive for repairs, shops can help clients determine “Should I fix it, or finally sell it?” with this data

Lansing, Mich.—U.S. vehicle owners are holding onto their cars longer as the average vehicle on the road is now more than 12 years old. But at around 120K–180K miles, many owners face the question, “Should I fix it, or finally sell it?” and rely on their service advisors and technicians for advice.

When a vehicle repair cost doesn’t offer overall value, shops can benefit by a stronger emphasis from “car care” to “customer care” and continue to build loyalty.

Using internal usage patterns across repair manuals for over 10,000 vehicle models, Repair Surge analyzed common repairs that offer a positive return on investment and identified which ones that signal it’s time to trade in. 

The data reveals:       

• The seven repairs that almost always pay for themselves in extended lifespan and resale value.     

• The repairs that rarely pencil out — even if the car is running well.      

• The vehicles that owners are most willing to keep repairing past 180K.     

• How repair ROI varies for Honda, Toyota, Ford, GM, and European models.      

• The real mileage at which the average vehicle hits a “value cliff.”

Repair Surges’ data shows that, based on an analysis of 2,400 repair scenarios, 92 percent of the time a repair is warranted, while the decision not to repair represents 8 percent. Here’s a brief breakdown of the findings and key takeaways. The sampling represents typical used vehicles in average cost-of-living areas and they are assumed to be in good condition with standard options.

Repair shops should advise their clients to do the math and compare their actual repair quote to the vehicle’s current value.

The average age of vehicles on U.S. roads hit a record high of 12.8 years in 2025, according to S&P Global Mobility, driven by high new/used car costs and better vehicle durability. In addition to higher average ages, Repair Surge also notes that a vehicle’s mileage is also a differentiator when assisting clients in making repair decisions.

Below are the repairs most likely to push vehicle owners into sell territory when high mileage is taken into consideration.

For more granular data, click here to download.

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