Are Car Manufacturers Secretly Undermining the Green Movement?
Valerie Raskovic
As the push toward environmental movement through sustainability gains momentum, many car manufacturers highlight improvements in fuel efficiency, electrification, and reduced emissions. While these advances are very important, it can seem a bit disingenuous because while the manufacturers are building more fuel-efficient vehicles, modern design and repair practices may be working against the broader goals of the green movement. The trend toward non-repairable components, limited parts availability and permanent assembly methods is raising questions about long-term sustainability.
The New Shift from Repair to Replacement
Nowadays it seems like a lot of manufacturers have figured out a new revenue model. Instead of building products and systems that can be repaired, they make it nearly impossible to repair some systems forcing the consumer to pay for a new one. In fact, it’s increasingly common for manufacturers to design systems, where entire assemblies must be replaced instead of fixing a single failed part.
Examples include everything from minor accessories to major systems such as the following:
- Drivetrain & Related Components
For example, some manufacturers, such as Mercedes-Benz, now require replacing the entire housing and related assemblies for what was once a simple PCV (Positive Crankcase Ventilation) check valve replacement. In fact, the entire hose and PCV assembly can only be purchased as one piece. Instead of letting the consumer replace just that little check valve the company has molded it into the assemblies, making it impossible for mechanics to separate the PCV valve from the hoses and other component without damage. Sadly, the act of grouping related parts together and calling it one part and ONLY giving it a single part number has become commonplace amongst many of the auto manufacturers.
The lack of available part numbers for subcomponents means the consumer is forced to spend more by replacing entire systems, making repairs that were once considered simple and inexpensive, costly and time-consuming. Not to mention that in many cases perfectly functional components are being discarded unnecessarily, creating waste some of which, due to the nature of its construction, cannot be recycled. Needless to say, this practice contributes to avoidable material waste.
- Body panels and trim
Built in obsolescence has affected almost every part of modern car design. A lot of plastic panels are now made with one-way plastic tabs, which are designed to break when disassembled. The issue with this is when once manufacturers used clips and screws, now the mounting hardware is built into the panels, forcing the consumer to buy a new panel or component every time it needs to be removed.
- Suspension components
Not allowing a consumer to buy an individual component, requiring them to buy the entire system, has become somewhat of a common practice in the automotive industry. Even when it comes to wear and tear, suspension parts that are commonly replaced at various service intervals may require the consumer to buy full assemblies. One of the best examples is a ball joint. Ball joints are pivoting connectors in a vehicle’s suspension that allow the wheels to move up and down while also turning left and right, enabling smooth steering and stable handling. As you can imagine, these are commonly replaced parts. Traditionally the manufacturers would allow you to buy them separately and install them in the control arm assemblies; however, in modern times most manufacturers have switched to selling the entire control arm, forcing consumers to replace major components that in most cases do not require replacement. This type of forced upselling is not just an issue with ball joints but with other suspension components that can only be purchased as full assemblies.
- Electronic modules
In some cases, there is a good reason why the manufacturer may not want any third party to service vital electrical components like ABS (Antilock Brake System) and PCM (Power Control Module) modules; however, making these components in such a way that they cannot be serviced even by the dealer who sold you the car seems a bit absurd. The only option for any type of electrical repair nowadays seems to be replacement of major electrical components or entire systems.
This departure from common repair to replacement has affected almost all systems commonly found in modern vehicles. The manufacturers have left the consumer no choice when a small component fails. The only option is often to replace the entire system, resulting in more waste and significantly higher costs.
The now common practice of using permanent bonding and non-serviceable design
Modern vehicles increasingly use permanent bonding technologies, such as structural adhesives and panel bonding, to improve rigidity, safety, and manufacturing efficiency. These modern bonding materials are part of the reason why a lot of newer cars have more of a solid feel to them, with more rigid bodies reducing rattle, squeaks and body panel misalignment in bodies. While these methods have some obvious benefits, they also introduce some serious drawbacks.
The issues arise once bonded; in most cases bonded components:
- Cannot be removed without causing damage.
- Require replacement as they cannot be removed without damage. Manufacturers know this and it is reasonable to assume this may be the reason they do not even offer a repair procedure for certain systems requiring full replacement of even larger components such as body panels. For example, certain body panels or structural components may need to be entirely replaced even when they sustained no damage and needs to be removed as part of a repair on another system or component. This does not only increase labor and material consumption during repairs; it also increases the waste.
Environmental Impact
These design trends have broader environmental consequences:
- Increased Waste
When entire assemblies are replaced instead of repaired, more materials end up in landfills, even if most of the component is still functional.
- Higher Resource Consumption
Manufacturing replacement parts requires a lot of resources, including raw materials, energy and transportation, significantly adding to the overall environmental impact.
- Shortened Product Lifecycles
Vehicles may become more expensive to repair, leading some owners to replace them sooner, increasing demand for new vehicle production, which uses up more materials and energy.
- The Conflict with Larger Sustainability Goals
While automakers are investing heavily in electric vehicles and emissions reduction, the repairability of vehicles is a commonly overlooked aspect of sustainability. It is safe to assume that it is overlooked for the purpose of cost cutting and revenue generation through part sales post-purchase.
If vehicle manufacturers whole-heartedly embraced the new green movement, they would consider doing things differently by:
- Extending vehicle lifespan
- Reducing waste through repairable design
- Supporting independent repair options
- Making parts more accessible
Without these considerations, major gains in one area (like emissions) may be offset by increased waste and resource use elsewhere.
What Consumers Can Do
While many of these vehicle design decisions are out of the consumer’s control, there are still some steps buyers can take to decrease a vehicle’s impact on the environment as well as their wallets.
- NEVER FORGET not all cars are created equal. While some Japanese car manufacturers like Toyota, Subaru and Honda tend to make cars and trucks that are more repairable, Stellantis brands as well as many of the German and British car manufacturers tend to push the consumer towards complete system replacement, complicating the repair and increasing cost.
- Just because the manufacturer does not offer a part number for a subsystem component does not mean it does not exist. By using a good, qualified repair professionals familiar with your make and model vehicle, it may be possible to repair a system rather than doing a complete replacement.
- Consider the long-term cost and sustainability of replacement parts; be sure to purchase quality parts from OEM (Original Equipment Manufacturer) suppliers.
The takeaway
Designing vehicles that can be maintained, repaired, and kept on the road longer is just as important as reducing emissions. Without addressing repairability, the industry risks undermining the very environmental goals it aims to achieve.
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