OK, forgive me for the National Enquirer headline, but that is the actual cost of the USPS electric mail trucks in use so far. The cost per vehicle will go down as more are made, of course, but it’s a pretty ugly picture thus far.
Currently, the United States Postal Service’s effort to electrify its mail truck fleet is facing mounting challenges as production delays, engineering setbacks, and political scrutiny threaten to derail one of the federal government’s most high-profile clean transportation initiatives.
In 2021, USPS announced plans to modernize its aging delivery fleet by purchasing more than 165,000 Next Generation Delivery Vehicles (NGDVs) over a 10-year period, with a growing share slated to be battery-electric. The program, part of a broader $10 billion investment to cut emissions and modernize infrastructure, included plans for at least 66,000 electric vehicles by 2028.
But as of now, progress has fallen far short of expectations. Only 250 electric NGDVs have been produced to date, with fewer than 100 delivered and in service. Contractor Oshkosh Defense, which is manufacturing the trucks at its new plant in Spartanburg, South Carolina, has faced repeated setbacks. According to internal reports and outside analysis, the facility is currently producing just one vehicle per day—well below the intended output of 80 trucks daily. Problems cited include airbag calibration failures, water leakage during quality control testing, and overall production inefficiencies.
So, let’s break down the numbers so far:
If you divide the $1.29 billion allocated for EV acquisition by the 250 produced, it equates to roughly $5.16 million per truck—even before factoring in any infrastructure costs. That figure does not include the nearly $1.71 billion spent on chargers and grid upgrades, which aren't easily attributable to individual vehicles. If you spread the infrastructure costs evenly, the combined total would soar to roughly $12.2 million per postal truck, so far.
The sluggish rollout has drawn bipartisan concern. Republican lawmakers have pushed legislation to claw back more than $1 billion in remaining funds earmarked for EV production and charging infrastructure. One bill, introduced in June, called for selling off newly built EVs and their support systems, citing cost overruns, operational delays, and limited field deployment.
Despite the pushback, the Senate parliamentarian recently ruled that the effort to defund the EV program would require 60 votes—making it unlikely to advance in a divided chamber that primarily votes along party lines. USPS has already committed more than $540 million to build out charging stations at hundreds of postal facilities across the country, and legal experts warn that reversing those investments could be both costly and disruptive.
The electric NGDVs, once hailed as a cornerstone of the Biden administration’s climate agenda, were designed to replace the Postal Service’s aging fleet of Grumman Long Life Vehicles, most of which lack air conditioning and are more than 30 years old. The new trucks offer a host of upgrades, including air conditioning, improved driver ergonomics, modern safety systems, and enhanced cargo capacity. Early feedback from postal workers has been positive, especially in hotter climates.
In addition to the NGDVs, USPS has taken delivery of approximately 8,000 battery-electric Ford E-Transit vans, which are being deployed in urban areas where charging infrastructure is already in place. Still, the number falls short of the agency’s broader electrification goals.
USPS officials say they remain committed to the EV transition but acknowledge the road has been more difficult than anticipated. “We are continuing to work with our suppliers to address production and performance issues and ensure a smooth deployment,” a spokesperson said.
With deadlines approaching and political stakes rising, the success or failure of the USPS electric fleet may hinge on whether Oshkosh can scale production efficiently—and whether Congress chooses to support or unwind one of the country’s largest government-funded EV efforts to date.
Photo: USPS.
.jpg?width=150&name=jerry-headshot.jpg%20(1).jpg)