A growing number of electric vehicle owners, particularly those operating ride-hailing or delivery services, are resorting to illegal modifications to extend their cars' declining battery range. This trend is creating a significant gray market, driven by the economic necessity of drivers who cannot afford official battery replacements or new vehicles.
For example, a ride-hailing driver in Beijing, whose vehicle's range has dropped from 300 km to 140 km after five years of use, faces a dilemma. A replacement battery from the manufacturer costs over 50,000 yuan, which exceeds the car's current resale value. Selling the vehicle used would only recoup about 30,000 yuan, not enough to cover the initial investment. This has led him to install an unofficial, external battery pack.
This situation is not isolated. As China's electric vehicle fleet surpasses 43 million units, the first large wave of commercial vehicles is experiencing severe battery degradation. High-mileage usage, such as in ride-hailing and delivery, accelerates this decline. While a family car might see a 10-15% range loss over six years, a commercial vehicle can suffer a 30-40% drop in just three to four years, sometimes falling below 60% of its original battery health.
The high cost of official battery replacements, often excluded from warranty coverage for commercial vehicles, and the even greater expense of buying a new car are pushing drivers toward unauthorized modifications. A supplier in this gray market revealed that over 80% of their business comes from commercial vehicle operators. Installing a 20 kWh auxiliary battery pack costs around 16,000 yuan, a fraction of the price of a new battery or vehicle.
However, these modifications carry severe safety risks and are explicitly illegal. Experts warn that such alterations bypass critical safety protocols. Risks include a significantly higher chance of thermal runaway, as aftermarket batteries lack proper thermal management systems. Added equipment can disrupt the vehicle's original Battery Management System (BMS), leading to overcharging or voltage instability. Furthermore, the extra weight can compromise the vehicle's structural integrity and handling.
Insurers typically deny claims for accidents involving illegally modified vehicles. There have been incidents, such as a fire in Jinan caused by a modified EV, resulting in substantial property damage.
A key question is why automakers do not offer official, safe range-extending solutions for older models. Industry insiders cite major barriers: the high cost of re-certifying old models for new components, complexities in warranty and liability, and a business model focused on selling new cars rather than upgrading old ones.
Policymakers are taking steps to address the root causes. New regulations are fostering a market for third-party battery repair, replacement, and remanufacturing, which could lower the cost of official solutions. The automotive aftermarket is also being guided toward standardization and legality.
Experts believe that as battery technology improves, charging infrastructure expands, and official battery replacement services become more affordable, the demand for illegal modifications will decline. The gray market is expected to gradually shrink as safer, compliant alternatives become available. Nonetheless, the immediate challenge remains: balancing the economic needs of drivers with critical public safety concerns while these longer-term solutions are implemented.
