For fleet managers, electric vehicles stand out as the smarter, more cost-effective, and sustainable solution. But with electrification come a few common lingering questions:

• Will an EV have the range to cover your longest routes?
• What charging setup keeps vehicles ready without affecting uptime?
• Does the total cost of ownership make the investment worthwhile?

While these concerns are valid, they’re rooted in outdated assumptions. In just a few years, the EV market has changed significantly, and with fuel costs remaining well above pre-2020 levels, many fleets face mounting pressure to cut operating expenses and align with tightening emissions standards.

Fleet managers are at a crossroads: stick with internal combustion engines (ICE) for predictability, or explore EVs as a way to significantly reduce costs and future-proof operations.

The best way to make that call is by looking at the data. Below is a deep comparison of EVs and ICE vehicles across several critical areas, including performance, cost, and sustainability.

What is an ICE vehicle? And how does it work?

An ICE (internal combustion engine) vehicle is powered by burning fuel, typically gasoline or diesel. It features a wide range of components, including:

• Engine and fuel components: Crankshafts, camshafts, fuel pumps, injectors, spark plugs, pistons, filters
• Transmission and drivetrain features: Clutches, gears, driveshafts
• Exhaust components: Mufflers, exhaust manifolds, catalytic converters
• Cooling elements: Radiators, thermostats, water pumps

For years, ICE vehicles have been the backbone of fleet operations. They’re widely available and supported by a mature fueling and maintenance infrastructure. They’re also familiar to both drivers and technicians, and that dependability is why many managers still view ICE as the safer, more predictable choice for their fleets.

What is an electric vehicle? And how does it work?

An EV (electric vehicle) runs on electricity instead of fuel. The electricity, usually stored in batteries, powers an electric motor, which converts the electrical energy into motion. Unlike with ICE vehicles, there’s no combustion, which means no energy lost as heat from burning fuel.

Some of the core components of an EV are:

• Battery pack: Stores electrical energy; capacity determines vehicle’s range and performance
• Electric motor: Converts electrical energy into mechanical energy
• Onboard charger: Converts AC power from charging stations into DC power to charge the battery pack
• Regenerative braking system: Captures kinetic energy during braking and converts it into electrical energy to recharge the battery
• Thermal management system: Maintains optimal temperatures in the battery pack and motor for performance and safety

EVs operate with far fewer moving parts than ICE vehicles. This simplicity translates to higher energy efficiency and less routine maintenance, which is why EVs are gaining traction in fleet operations globally.

EV vs. ICE: Total cost of ownership (TCO)

Total cost of ownership (TCO) encompasses all the costs related to owning and using a vehicle through its entire lifecycle: upfront purchase or financing costs, insurance expenses, day-to-day maintenance costs, the impact of depreciation, registration, and any other relevant fees.

TCO = Acquisition Costs + Operating Costs + Maintenance Costs – Incentives – Residual Value

When investing in fleet vehicles, TCO is the most important consideration because it determines the financial impact of your investment over a long-term period.

While EVs generally have higher upfront costs than ICE vehicles because of their charging and battery technology, Harbinger EVs are competitively priced and designed to achieve parity on acquisition cost. In addition, Harbinger helps fleets lower operating and maintenance expenses and offers superior uptime.

There are incentives in certain states to help narrow the upfront price gap. These initiatives include, but aren’t limited to:

• California: Clean Truck and Bus Voucher Incentive Project (HVIP)
• New Jersey: Zero-Emission Incentive Program (ZIP)
• Massachusetts: Massachusetts Offers Rebates for Electric Vehicles (MOR-EV)
• Oregon: Zero-Emissions Rebates for Oregon Fleets (ZERO Fleet)

With EVs, the charging method also plays a role in TCO. Level 2 (L2) chargers generally offer the lowest electricity cost per mile. DC fast chargers are more flexible, but with the tradeoff of longer utility delays and more battery wear. Due to their speed, Level 1 (L1) chargers are typically not used on their own for fleets, but may be paired with L2 chargers.

Here’s a quick, at-a-glance breakdown of TCO for EVs vs. ICE vehicles:

	EVs	ICE vehicles
Electricity or fuel costs	$0.225/mi / $0.107/mi (Harbinger EVs)	$0.398/mi (diesel) / $0.495/mi (gas)
Repair and maintenance	$0.171/mi (Harbinger EVs)	$0.216/mi (diesel); $0.218/mi (gas)
Incentives	~$30,000–150,000 (varies by state and vehicle class)	N/A

These considerations cover upfront and ongoing costs, but residual value is another factor. While it varies by vehicle and battery or engine health, EVs are positioned for higher long-term value as the market shifts toward zero-emission fleets.

Energy efficiency

Energy efficiency directly influences fuel spend, operating costs, and total cost of ownership. The more efficiently a vehicle converts input energy into motion, the less money you waste.

EVs in general convert a significantly higher share of their energy into propulsion, with only about 9–13% lost in the process. Harbinger EVs push this further, converting 94% of their energy into propulsion — a class-leading efficiency rating. Regenerative braking further reduces waste by capturing energy that would otherwise be lost during deceleration.

ICE vehicles lose most of their input energy as heat. Gasoline engines typically waste up to 70%, while diesel engines lose 50–60%. That inefficiency translates to higher fuel consumption and operating expenses, as well as uptime lost to more frequent refueling.

EVs incur roughly 47% lower costs compared to diesel and 53% compared to gasoline. However, savings vary by region. In high-cost states like California, EVs can produce annual savings of ~$12,700, while in low-cost states like Tennessee, annual savings are ~$9,400. When compared to diesel costs, EVs save thousands of dollars per vehicle.

Performance considerations for commercial fleets

The biggest performance differences between EVs and ICE vehicles show up most clearly in torque delivery, ride quality, operational impact, and payload.

• Torque: EVs deliver instant torque, which is especially great for stop-and-go driving. Acceleration is slower in ICE vehicles because their engines need to reach a specific RPM to produce power.
• Ride quality: EVs have less vibration than ICE vehicles. This is partly because they have fewer components than ICE options, and unlike gas and diesel vehicles, they don’t rely on combustion to produce power. Less vibration means quieter and smoother driving experiences, which can reduce driver fatigue.
• Operational impact: For fleets, the smooth acceleration of EVs can improve safety for drivers and cargo, reducing the risk of downtime resulting from accidents or damaged goods.
• Payload: EVs tend to have a lower payload capacity than ICE vehicles. However, Harbinger’s EVs are engineered differently, with a light and compact EDU and superior gradeability that outperforms Class 6 competitors.

Maintenance and service considerations

ICE trucks rely on thousands of moving parts (engines, transmissions, exhaust systems, cooling systems, etc.), each with its own schedule for maintenance and repair. However, this also means thousands of potential points of failure and more time spent in the shop.

With far fewer fluids and moving components, EV maintenance demands are lighter and more predictable. Regenerative braking also means less wear on brake pads and rotors, providing longer intervals between replacements and less money spent on brake service.

While lower service costs are an advantage, the real advantage is higher uptime. Less time in the shop means more vehicles on the road and more productive fleets.

Here’s a side-by-side look at the most common service needs for each type of vehicle:

	EVs (Harbinger)	ICE vehicles
Filter and oil change	N/A	Every 3,000 to 5,000 miles
Fuel filter replacement	N/A	Every 30,000 miles
Spark plug replacement	N/A	Every 30,000 miles
Coolant service	Flush at 100,000 miles	Flush every 30,000 to 60,000 miles
Tire rotation	Every 10,000 miles	Every 4,000 to 5,000 miles
AC refrigerant service	Check annually	Check annually
Brake fluid	Flush at 30,000 miles	Flush every 30,000 miles
Drive unit mount	Replace every 250,000 miles	Needs vary; inspect during routine maintenance

Sustainability and emissions: Fleet impact

EVs aren’t emission-free — OEMs do produce emissions during their manufacturing process. However, they operate with far fewer emissions than ICE vehicles, making it easier to achieve your fleet’s sustainability goals.

EVs outpace ICE vehicles in environmental impact because they produce zero tailpipe emissions. Whereas, the burning of fuel in ICE vehicles releases significant amounts of carbon dioxide and nitrogen oxide.

Infrastructure and range

For fleet operators, fueling and charging infrastructure directly affect route planning and uptime. ICE vehicles have a mature fueling network, with refueling available in most places, which simplifies long-haul and variable route planning. The EV charging ecosystem is rapidly maturing, with public charging stations available across most major routes. Charging depots keep fleets charged during scheduled downtime, and with DC fast charging (up to 180 kW), an EV can recharge from 20% to 90% in under an hour.

Range predictability is another key difference. For both EVs and ICE vehicles, range can fluctuate depending on factors like traffic, idling, and driver behavior. However, EVs offer consistent per-charge mileage range tied to route design and charging strategy, whereas range for ICE vehicles depends on fuel economy. In practice, this means EVs and ICE vehicles both require upfront route optimization, but once configured, EV performance is more predictable and less wasteful.

Hybrid solutions as a bridge to full electrification

Hybrid solutions offer the best of both worlds, combining an electric drivetrain with a supplemental internal combustion engine.

Hybrids allow vehicles to run on battery power for short, local, or predictable routes while using the onboard engine as a backup for extended range. This flexibility makes them especially valuable for fleets handling long-distance or variable routes, as well as those operating in regions with limited charging networks. Hybrids give managers a way to cut fuel costs and emissions without compromising uptime.

Harbinger’s plug-in hybrid platform for medium-duty fleets is designed as a transitional solution, giving fleets the range and flexibility of an ICE with the efficiency benefits of electrification.

With Harbinger’s plug-in solution, fleets benefit from:

• Range extension: Features a 1.4L gasoline engine and generator, increasing the driving range to ~500 miles, making it suitable for long and unpredictable routes.
• Fueling and charging flexibility: An 800-volt electrical architecture that uses the same charging infrastructure as EVs, plus a gasoline engine that promotes reliability.
• Lower costs and emissions than ICE vehicles: The engine generates electricity while electric motors power the wheels, reducing fuel usage, total emissions, and maintenance costs.
• Flexible modes: Four modes: EV Mode (generator off), Hybrid Mode (generator assists), Stationary Mode (generator powers loads/charges while parked), Quiet Mode (ideal for camping)
• Streamlines EV transition: Test whether electrification is ideal for your fleet by gaining EV benefits without sacrificing range certainty.

Chart a path toward electrification with Harbinger

ICE vehicles may have a mature fueling network and familiar service infrastructure, but that comes with higher operating costs, more downtime for maintenance, a bigger carbon footprint, and greater exposure to fuel price volatility. EVs deliver lower operating costs, simpler maintenance, and more predictable efficiency — all while helping fleets meet sustainability goals.

Harbinger makes the transition practical. Unlike competitors that use retrofitted ICE vehicle designs, Harbinger’s products are purpose-built for medium-duty electric applications. With lower operating expenses, competitive pricing and access to state level expenses, Harbinger’s chassis delivers a total cost of ownership advantage that diesel simply cannot match. Harbinger also ensures quality control and supply chain reliability by manufacturing all electric drive units, battery packs, and chassis in the U.S.

For fleets seeking flexibility, Harbinger offers the industry’s first 500-mile plug-in hybrid platform. This solution combines the cost and efficiency benefits of electric propulsion with the extended range and refueling certainty of gasoline, providing a practical bridge for fleets that want to begin electrifying without sacrificing operational confidence.