When to Replace vs. Repair a Motor

Deciding whether to repair or replace an electric motor isn’t always straightforward. With budget constraints, critical timelines, and operational risks to consider, making the right choice can have a big impact on both your plant’s uptime and your bottom line.

Here’s a breakdown of the key factors to weigh when determining if it’s better to repair your motor—or replace it entirely.

1. Cost of Repair vs. Replacement

The first step is comparing repair costs to replacement costs. As a general rule:

• If the repair estimate exceeds 60–70% of the cost of a new motor, replacement may be the better long-term investment.
• However, for large HP or custom motors with long lead times, even higher repair costs may be justifiable.

Tip: Always factor in freight, installation, alignment, and commissioning costs for both options—not just the motor itself.

2. Age and Service History

How old is the motor? Has it been repaired multiple times before? A motor nearing the end of its expected service life (typically 15–20 years for industrial motors) may be more prone to repeated failures—even after a quality repair.

Ask yourself:

• Has this motor been reliable until now?
• Has it already had a major rewind?
• Are parts still readily available?

If reliability has been declining or it’s become costly to maintain, replacement should be considered.

3. Lead Time and Urgency

If a replacement motor is available from stock and downtime is critical, that may sway the decision toward replacement.

However, in many industries—especially mining, utilities, and oil & gas—replacement motors can take weeks or even months to arrive. In these cases, a fast repair from a certified shop may be the best (or only) viable option.

At Continental, we'll help you evaluate both options so you can make the right decision. 

4. Energy Efficiency Gains

New motors, especially premium-efficiency (IE3 or IE4) models, often consume significantly less energy over their lifespan. If your existing motor is older and running 24/7, the energy savings from a new high-efficiency motor may justify the upfront cost of replacement.

Bonus: In some regions, utility rebates are available for upgrading to high-efficiency motors.

5. Application Criticality

For non-critical applications (like backup or spare motors), a cost-effective repair may be more than sufficient.

But for critical systems—think main production lines, compressors, or process-critical fans—it’s often worth investing in a new motor to ensure reliability and minimize the risk of recurring issues.

How Continental Can Help with your repair vs replace dilemma 

At Continental, we don’t just offer repairs or sales—we help you make the right decision based on your specific situation. Our team can:

• Perform a full condition assessment of your motor
• Provide side-by-side repair vs. replacement cost analysis
• Source new motors from trusted brands (ABB, Innomotics, WEG, TECO-Westinghouse)
• Expedite emergency repairs with full diagnostic and testing capabilities

Whether it’s 600V or 13.8kV, we’ll help you make the choice that protects your uptime, your budget, and your peace of mind.

Have a motor you’re unsure about?
Let’s take a look. Send it in for inspection or schedule an on-site evaluation—we’ll give you the insight you need to make the right call.

Want a different perspective?  Read what Matt Fletcher has to say about the topic here!