When to Replace Your Electrical Panel: A Homeowner’s Guide
Your electrical panel is the heart of your home’s electrical system. It distributes power, protects circuits, and keeps your house running safely. But panels don’t last forever — and most homeowners don’t know when theirs is overdue for replacement.
This guide gives you the clear signs and situations where a panel upgrade becomes necessary.
⚡ 1. How long does an electrical panel last?
Most panels last 25–40 years depending on:
the brand
your home’s electrical demand
environmental exposure
grounding and bonding quality
If your panel is older than 30 years, it’s worth getting it checked — age alone puts it into the “high-risk” category.
🚫 2. Panels that should be replaced immediately
Some panels are unsafe by design and should be upgraded regardless of condition:
Zinsco / Sylvania
Federal Pacific (FPE)
Pushmatic / Bulldog
Panels with visible overheating or melted components
These are known to fail to trip during overloads — a serious fire risk.
🔍 3. Signs your panel needs replacement
You don’t need to be an electrician to notice warning signs. Look for:
• Frequent breaker tripping
Indicates overload or worn-out breakers.
• Burning smell or discoloration
Heat damage, loose connections, or breaker failure.
• Rust or corrosion
Moisture intrusion — panel is compromised.
• Buzzing or crackling noises
Electrical arcing.
• Breakers that won’t reset or feel loose
Mechanical failure inside the panel.
• No more breaker spaces
If everything is tandem breakers, the panel is maxed out.
• Old wiring or outdated service equipment
1960s–1980s equipment often can’t support modern loads.
🔧 4. Situations where a panel upgrade is required
1. Installing an EV charger
Most EV circuits require 40A–60A. Older 100A services often can’t handle this.
2. Adding AC or a heat pump
Large appliances push older panels past safe limits.
3. SDG&E undergrounding in your neighborhood
If your home is converting from overhead to underground service, SDG&E may require:
panel modernization
new meter socket
grounding upgrades
panel relocation
This is one of the most common triggers for mandatory panel upgrades.
4. Major remodels
Permits often require electrical service to meet current code.
5. Insurance requirements
Some insurers refuse coverage on FPE, Zinsco, or old 60A/70A services.
🔌 5. What size panel do most homes need today?
Typical modern requirements:
125A = minimum for older homes being upgraded
200A = standard for EVs, AC, heat pumps, and future-proofing
Going 200A is usually the smartest long-term move.
💰 6. How much does a panel replacement cost?
San Diego averages:
$4,500–$7,500 = typical range
$7,500+ = relocation, trenching, or complex grounding issues
Cost varies based on:
location
age of equipment
grounding/bonding
accessibility
permitting
type of service (overhead or underground)
🏠 7. How to know for sure
A licensed electrician can evaluate your panel by checking:
brand
age
condition
meter socket
grounding system
wiring condition
service capacity
load demands
Photos alone are often enough to determine whether an upgrade is necessary.
✅ Final Thoughts
Your panel is the safety foundation of your entire electrical system. If it’s old, obsolete, or showing warning signs, upgrading is one of the most important improvements you can make for safety and reliability.
