Why Converting Trucks May Beat Buying New EVs

A new partnership promises faster, cheaper fleet electrification by converting existing trucks instead of replacing them

4 Sep 2025

A partnership announced in September 2025 points to a quicker way for US fleets to go electric. Instead of waiting for new trucks to arrive, operators can convert vehicles already in service.

RePower Electric and Fuel2Electric unveiled the collaboration in a joint announcement. The message was clear. Conversions can help fleets respond to tighter emissions rules, fuel price swings, and public pressure without blowing up budgets.

The idea is simple. Keep the truck. Swap the powertrain. RePower Electric provides the conversion systems, while Fuel2Electric handles sales, installation, and support through a nationwide service network. The goal is to tackle two familiar problems at once: steep upfront costs and slow replacement cycles.

“This approach lets fleets act now instead of waiting,” Fuel2Electric said when outlining the deal. RePower Electric has made a similar case, arguing that conversions extend vehicle life while cutting emissions and operating costs.

Timing matters. Many commercial vehicles, especially in transit, school buses, and city services, stay on the road for 15 to 20 years. Replacing them early with new electric models can strain finances and delay climate plans. Conversions offer a middle path. Fleets electrify sooner and avoid scrapping usable assets.

Early pilots suggest the model can work. Regional delivery fleets and municipal vehicles have logged lower fuel spending and eliminated tailpipe emissions, all while keeping familiar platforms in service. These trials also help operators test performance, maintenance needs, and real world savings before expanding.

Analysts see the partnership as part of a broader shift toward practical electrification. Factory built electric trucks remain vital for the long run. Retrofit options can bridge gaps as supply chains, charging access, and prices continue to evolve. That flexibility is especially attractive to smaller fleets and local governments.

Challenges remain. Compliance rules vary by state. Warranty terms can be complex. Scaling conversions across many vehicle types is not trivial. Still, advances in electric systems are making large retrofits more feasible.

As emissions deadlines near, solutions that blend speed, cost control, and flexibility are gaining traction. For fleets under pressure to move, electrification may no longer have to wait for the next new truck.