How Are EVs Changing The Tow Truck Industry?

The rise of electric vehicles (EVs) is reshaping nearly every corner of the automotive world—and the tow truck industry is no exception. While EVs promise efficiency, reduced emissions, and low maintenance, they also introduce a new set of challenges when it comes to roadside recovery and towing. Unlike traditional internal combustion engine (ICE) vehicles, EVs often lack a neutral gear, are significantly heavier, and contain sensitive electronics and battery systems that demand special care.

At CHUSHENG VEHICLE GROUP CO., LTD., we understand how quickly the towing landscape is evolving. With more drivers making the shift to electric mobility, the need for purpose-built EV-compatible tow trucks is growing rapidly. In this article, we’ll explore the differences between towing EVs and ICE vehicles, the equipment required, the technological advancements in the industry, and how our company is leading the way with EV-savvy solutions.

What Makes Towing EVs Different from ICE Vehicles?

Towing an EV is not as straightforward as towing a traditional gasoline or diesel vehicle. Several key differences affect the recovery method:

1. No Neutral Gear
Many EVs do not feature a true mechanical neutral. Their electric drivetrains engage the wheels even when the car is "off." This makes conventional wheel-lift towing highly risky, as it can lead to drivetrain or motor damage if the vehicle is moved with its wheels on the ground.

2. Regenerative Braking Systems
EVs are equipped with regenerative braking systems that engage when the wheels rotate—potentially creating electrical feedback if towed improperly. This can result in damage to the electronic control unit (ECU) or motor inverter.

3. Battery Sensitivity
High-voltage lithium-ion batteries can be dangerous if handled incorrectly. Damaged or over-disrupted batteries pose fire risks and must be transported with care.

4. Increased Weight
EVs are typically 20–30% heavier than ICE vehicles due to their battery packs. This impacts the tow truck’s lifting, braking, and transport capabilities, requiring reinforced platforms and hydraulic systems.

As EVs continue to gain market share, tow truck operators must adapt to avoid vehicle damage, insurance claims, and reputational loss.

What Equipment Is Needed for Safe EV Recovery?

Towing EVs requires the right equipment—both to protect the vehicle and to ensure safety during transport. Flatbeds are often the only acceptable solution for most modern electric cars.

1. Flatbed Tow Trucks
Flatbeds allow all four wheels of the EV to remain off the ground, avoiding any potential damage to the drive motor or regen system. A low-angle tilt bed is preferable to accommodate EVs with low ground clearance, such as Teslas or sports EVs.

2. Freewheeling Dolly or Hub Tools
In rare cases where a flatbed isn’t available, specially designed freewheeling hub tools can disengage the wheels from the motor, allowing safe wheel-lift towing. However, this is only feasible with trained operators and compatible EV models.

3. EV-Specific Boost Chargers
EV drivers sometimes require charging, not towing. Onboard EV boost chargers can provide enough power to drive the vehicle to a nearby station. Modern tow trucks increasingly include this feature as part of their service offering.

At CHUSHENG, our flatbed tow trucks are engineered with reinforced platforms, precision winch systems, and EV-friendly loading angles. These designs ensure safe and seamless transport of even the most advanced electric vehicles.

How Are Tow Trucks Adapting Technologically?

As EVs evolve, tow truck manufacturers are also innovating. New technologies are emerging to meet the demands of electric vehicle recovery—enhancing efficiency, safety, and performance.

1. In-Van Charging Systems
Some advanced tow trucks now come equipped with onboard charging stations. These allow operators to provide a limited power boost to stranded EVs, helping them reach a nearby charging station rather than being towed.

2. Regenerative Tow Charging (In Development)
Experimental models are exploring regenerative braking systems for tow trucks themselves. These systems recover energy during deceleration and can be used to help power auxiliary systems like winches, hydraulic lifts, or charging inverters.

3. Real-Time Diagnostic Tools
Advanced tow trucks are integrating digital diagnostics that can connect to an EV’s onboard computer to read battery levels, unlock charge ports, or disengage brakes.

4. Touch-Safe Control Interfaces
Because of the high-voltage risk in EV systems, newer tow trucks use shielded electronics and ergonomic controls to minimize exposure to electric hazards.

At CHUSHENG VEHICLE GROUP CO., LTD., we’re actively innovating in this space. Our latest flatbed models are built with EV readiness in mind, supporting tool integration, touch-safe wiring, and modular designs for custom upgrades.

What Are Industry Challenges with EVs?

Transitioning to EV-compatible towing presents several challenges, especially for traditional towing fleets and smaller operators:

1. Heavier Loads
The extra weight of EVs demands stronger winches, reinforced axles, and hydraulic upgrades. Not all existing tow trucks can handle the added burden safely or legally.

2. Specialized Training
Tow operators must learn how to safely disable an EV, recognize high-voltage components, and follow manufacturer-specific recovery procedures. A single misstep could damage a $40,000 battery system—or worse, injure the operator.

3. Limited Recovery Information
Many EV manufacturers still don’t provide clear towing procedures. This lack of standardization makes it hard for operators to respond quickly and safely across different EV brands.

4. Battery Fire Risks
Improper towing, especially post-accident, can increase the chance of a battery fire. Special battery containment blankets or fire-suppressant kits may be necessary in some cases.

5. Legal & Insurance Concerns
Towing companies must update their insurance policies to cover the unique risks associated with EVs, and local regulations may require updated permits or inspections for EV-specific equipment.

CHUSHENG helps mitigate these challenges by offering EV-ready vehicle designs, easy operator training support, and scalable fleet solutions tailored to modern recovery demands.

How Should Drivers Prepare Their EV for Breakdown?

EV owners can also play a role in ensuring smooth and safe towing by understanding their vehicle’s specific needs.

1. Know Your Vehicle's Recovery Points
Not all EVs have visible tow hooks or traditional access points. Owners should familiarize themselves with where recovery points are located and how to make them accessible during an emergency.

2. Understand Your Roadside Policy
EVs are sometimes excluded from standard roadside plans or require premium service levels. Drivers should ensure their plan includes EV-specific coverage and preferred towing methods.

3. Plan for Range and Charging
Running out of battery is one of the most common reasons for EV towing. Drivers should plan routes with adequate charging stations and monitor battery health.

4. Use Certified EV Towing Providers
Some towing services specialize in electric vehicle recovery. Partnering with a certified or manufacturer-approved service can reduce the risk of improper towing.

By educating drivers and upgrading tow fleets, the industry can safely evolve alongside the EV market.

Conclusion

Electric vehicles are accelerating the transformation of the tow truck industry. From flatbeds designed for low-clearance EVs to in-van charging and smart diagnostics, tow trucks are becoming smarter and more specialized than ever before. With new challenges such as drivetrain protection, weight handling, and high-voltage safety, only modern, well-equipped tow trucks can meet the demands of this electric age.

At CHUSHENG VEHICLE GROUP CO., LTD., we’re proud to offer a growing line of EV-compatible tow trucks built for the future. Whether you're expanding your fleet or upgrading for EV readiness, our advanced designs, safety features, and customizable systems will keep you ahead of the curve.

Contact us today to learn more about our EV-friendly tow trucks and find the best model for your business or fleet.