Electric vehicles roll into service departments for all sorts of reasons including software glitches, dead 12-volt batteries, collision repairs, and high-voltage concerns. But before any of that work begins, many EVs take a detour to a tow operator’s flatbed. And unlike ICE vehicles, the towing requirements for EVs aren’t simply recommendations. They’re safety precautions that protect the car, the technician, the tow operator, and every component in that high-voltage system.
If you’re a service manager, advisor, or technician working with EVs, understanding why flatbed towing matters and what can go wrong when it’s done incorrectly is essential knowledge. Here we break down safe towing procedures, explain common risks, and highlight the diagnostic steps your shop should follow once the vehicle arrives.
Why EVs Need Flatbed Towing
Most EVs can’t be towed with two wheels on the ground or with their drive wheels spinning freely. Even when the vehicle is set to neutral, that mode doesn’t work the same way it does in traditional vehicles. In most EV platforms, the motor remains directly connected to the drive wheels, which means towing the vehicle can force the motor to rotate, and that creates problems.
Here’s what can go wrong:
- Motor overspeed – When the rotor spins faster than intended, physical damage can occur inside the motor. This damage isn’t always immediate or obvious. Sometimes it shows up later as vibration, noise, or inverter faults that leave technicians puzzled.
- Unintended energy generation – Spinning wheels can cause the motor to act like a generator. This feeds voltage back into the high-voltage system while the control modules are offline. That can damage inverters, fast-charge circuits, or the battery pack itself.
- Damaged reduction gears – Many EV drivetrains rely on reduction gears rather than multi-speed transmissions. These gears need lubrication and precise operating conditions. Forced rotation during towing can result in wear or catastrophic failure.
- Unpredictable contactor behavior – If the system senses unexpected motor rotation, the vehicle may attempt to energize or isolate systems in ways you don’t want.
A flatbed eliminates all these risks by keeping the wheels from spinning altogether. Some EVs allow limited dolly towing under specific OEM instructions, but most manufacturers still recommend or require flatbed transport whenever possible.
Preparing an EV for Towing
Tow truck drivers and service staff need to treat EV towing as a process in itself, not a quick hookup to get it to the shop. Before loading the vehicle, ensure it’s stable, disengaged, and electrically safe.
- Confirm the EV is powered down. Tow truck drivers need to verify that the vehicle is fully off. EVs don’t always power down instantly when the driver walks away. If possible, move the key fob far away from the vehicle so the car doesn’t inadvertently wake up.
- Activate Tow Mode or Transport Mode. Some EVs have a specific setting that releases the parking brake, frees the brake system, or adjusts stability control. Others need to be done manually or by a scan tool if the 12-volt battery is dead.
- Secure the wheels. Wheel straps are preferred over hooks for EVs. Chassis points designed for towing are sometimes limited or not intended for long-distance transport. Wheel straps keep the load stable without risking damage to the underbody, battery pack enclosures, or aero panels.
- Use correct winch attachment points. Many EVs include recovery points behind covers. Attaching a winch hook to an incorrect location can crack cooling lines, distort the battery tray, or damage sensors.
Risks of Improper Towing
Even a short improper tow can cause long-term consequences. Here are the most common risks your shop may see when an EV wasn’t transported correctly:
- Motor and inverter damage – If the drive wheels spun during the tow, the vehicle may arrive with no immediate trouble codes, yet fail later under thermal or electrical stress. This can create expensive warranty claims and confusion to diagnose.
- Battery pack overheating – If regenerative current is pushed back into the battery during a tow, the pack could heat up or trigger internal protection measures. In severe cases, high-voltage fuses can blow, or modules can lock up.
- Parking brake or brake system damage – Dragging an EV with an engaged parking brake is more common than many shops realize, especially if the 12-volt system died before the tow operator arrived. Expect burned brake pads, overheated calipers, or damaged electronic brake actuators.
- Underbody panel damage – EVs have aerodynamic panels that hide high-voltage components, cooling parts, and wiring. Incorrect hook points or poorly positioned dollies can crack the pack shield or its mounting hardware.
- Diagnostic confusion – Improper towing can generate fault patterns that resemble inverter failures, battery isolation issues, or thermal management faults. Without a transparent history, your technicians could be chasing phantom problems for hours.
What Shops Should Do When an EV Arrives
The towing procedure may be complete, but the safety process for the shop is just beginning. Service personnel should assume nothing about the vehicle’s condition and confirm that high-voltage systems are stable before starting diagnosis.
- Assess the 12-volt battery first. Tows often involve a depleted 12-volt battery. Without low-voltage support, the EV’s contactors can’t close, and essential control modules may not boot. Use Midtronics testing equipment to evaluate the battery’s state and recover or replace it if needed.
- Verify HV status. Check the high-voltage isolation status, pack readiness, and contactor state using OEM scan tools or supported diagnostic tools.
- Look for towing-related trouble codes. If the EV was improperly towed, you may see wheel speed sensor mismatches, motor overspeed codes, or inverter current anomalies.
- Inspect underbody panels for damage. Tow straps, hooks, or dollies can damage the pack shield. If the pack enclosure is dented, scratched, or bent, consult OEM safety documentation before continuing.
Communicating Towing Risks to Customers
Most customers simply assume that towing is towing. They don’t understand the risks of dragging an EV behind a truck or allowing the wheels to roll freely. Service advisors should take a moment to explain any concerns discovered during intake.
Here’s a simple way to explain it: “Your EV has to be transported on a flatbed because the motor and drivetrain are always connected to the wheels. If the wheels spin while the car is off, it can damage the high-voltage system. We’re going to check the vehicle over to make sure nothing unusual happened during transport.”
Clear communication like this helps avoid frustration and builds trust by showing that your shop understands EV-specific needs.
Midtronics in EV Workflows
Once an EV arrives at your shop after a tow, the first step toward accurate diagnosis is verifying system readiness. That starts with a healthy 12-volt battery and a stable high-voltage environment. Midtronics EV diagnostic tools give your technicians the confidence to bring an EV online safely, confirm whether any electrical issues were caused during the tow, and guide the next steps in the diagnostic or repair process.
Accurate low-voltage analysis, high-voltage procedures, and safe charging processes all depend on reliable testing equipment. Midtronics tools help service teams reduce comebacks, improve safety, and protect high-value EVs and their components to leave no room for guesswork.