Understanding Extended-Range Electric Vehicles (EREVs)

At the new 2025 Lincoln Navigator’s Monterey Car Week debut, we had the opportunity to catch up with Ford CEO Jim Farley and a couple of top Ford executives. Hot topics of conversation included Chinese EVs, of course, but also extended-range electric vehicles (EREVs) and their suitability for the Chinese and possibly, U.S. markets. As Farley noted in our conversation, among Chinese electrified auto makers, only BYD and Li Auto are profitable, on the strength of diverse powertrain offerings, including hybrids, PHEVs, and EREVs.

While Farley gave no specific guidance in our conversation, he did advise us to “watch out for more news coming soon.” Perhaps he meant the subsequent announcement by Ford on its pivot away from a large, three-row battery-electric SUV in favor of a platform of hybrid-powertrain SUVs.

Ford already makes hybrid and electric trucks (Maverick and F-150 Lightning), plug-in hybrid (PHEV) SUVs (Escape), so could EREV technology be coming to future three-row SUVs such as the Explorer and Expedition nameplates as well as the F-series truck family? Possibly, says Sam Abuelsamid, principal research investigator for Guidehouse Insights. Abuelsamid speculates that EREV technology would be a great fit for Ford’s F-series platforms, including Super Duty. And this aligns Ford’s announcement in June 2024 that it plans to manufacture Super Duty trucks with “multi-energy technology” at its Oakville, Ontario plant.

What Is an EREV, and How Does It Differ from PHEV Tech?

So, what’s the difference between an EREV and, say, the plug-in hybrids you see everywhere today? A plug-in hybrid is basically a normal gas-electric hybrid with uprated electric components capable of propelling the vehicle along using only the motor and battery for relatively short distances (compared to, say, full-on EVs) but farther than a non-plug-in hybrid might manage. When the battery is depleted, the gas engine rejoins the driving process, and the vehicle operates like a conventional hybrid; however, you can plug it in again, charge the battery, and drive on electric power alone until the EV-only range runs its course. Today’s best PHEVs can achieve up to 40 to 50 miles of range, though most fall in the 15 to 30-mile zone. An extended-range EV is different—it’s fundamentally an electric vehicle, one that you still plug in to charge, but with an internal-combustion engine onboard that can act as a generator, producing enough electricity to extend the driving range beyond that afforded by the battery’s capacity alone.

The allure of EREVs lies in their engineering capabilities. They can be configured with smaller, more cost-effective batteries suitable for normal daily commuting or hauling duties, with the range extender kicking in to cover those sporadic longer trips or heavier loads. This configuration is particularly advantageous in larger vehicles, which can accommodate essentially two powertrains and already possess considerable weight. Additionally, trucks have broader performance envelopes than smaller vehicles, thus pure-electric versions require heavy and costly battery packs to deliver even modest range when towing; this leads to diminishing returns as increased weight compromises payload and towing capabilities. EREVs allow for more reasonably sized batteries to cover most driving tasks while using a gas engine for more energy-intensive operations, such as towing a tall camping trailer or navigating prolonged inclines. Moreover, the output and capability can be enhanced with a higher-performance engine/generator setup, instead of merely adding more batteries.

Advantages of EREV

What would be the advantages of EREV trucks and SUVs over pure battery electric options? Cost savings and capability, according to Abuelsamid, referencing Ram’s 1500 REV electric and Ramcharger EREV trucks as prime examples.

Abuelsamid outlines that “The standard Ram REV will have a 160-kWh battery. You can reduce that to a 90-92 kWh battery for the Ramcharger and save about $7,000 off the vehicle’s cost. Then by adding a [gas] Pentastar V-6, optimized for this function and effectively used as a generator, the additional expense may only be around $3,500-4,000. Thus, you’re looking at a savings of approximately $4,000 in creating a Ramcharger compared to the standard-range version of the Ram REV.”

“The base electric range is typically 140-150 miles, covering all your regular driving needs. With the range extender, you can achieve an additional 400-500 miles, enabling towing similar to a traditional gas or diesel truck. With this setup, you alleviate the concern of locating a charging station as you can simply refuel with gas again,” Abuelsamid elaborates. The Ramcharger aims to provide 690 miles of total range, differing from strictly electric trucks, which often see range declines when towing or hauling; having the gas engine onboard means the Ramcharger can tow longer distances without the usual anxiety associated with finding charging facilities. A quick five-minute stop at a gas station offers a far more convenient option than waiting at a charger.

Could Ford Have Opted for EREVs Over Large EVs?

It is plausible that Ford is shifting focus to more cost-effective EV options. The EREV format appears to be particularly suitable for large SUVs and trucks. Although an EREV powertrain typically presents more complexity than a purely electric configuration, managing battery sizing to meet specific targets (especially within the truck segment) can often result in higher costs and added weight compared to an EREV setup. Similar to plug-in hybrids, EREVs effectively mitigate public concerns surrounding range and recharging obstacles to electric vehicle adoption, making them an appealing choice for many consumers.