Ford's PHEV Fusion was identical in price for hybrid and non-hybrid drivetrains.

in, what, 2010? So ... no. Hybrids aren't necessarily more expensive, they were really only substantially expensive because Toyota dealers price gouged so much for them. If the US Government (Bush was in power, so not a chance of it happening) or California had mandated Hybrid/PHEV for all consumer cars by 2015 back in year 2000, the world would have been in a much better place today.

If hybrids had been mandated earlier, we would probably see a semi-electric car with 50-100 miles of all electric range and a compact charging rotary motor range extender. BMW was close but they were also too incompetent to close the gap from their whacko i3 to a really useful long range PHEV.

Tesla's per vehicle margin is allegedly the highest in the business, and their cars, while once priced in the "low luxury" segement, are pretty much the same or less than the average cost of a new car, which is at $48,000 right now.

Maintenance costs are theoretically much better, you may be right they aren't practically since Tesla build quality is still suspect.

These figures are all for previous generation battery economics. High density LFP/LMFP and Sodium Ion batteries will place EV drivetrains fundamentally under the cost of an ICE. These cells, already in mass production, will be half to 1/3 the cost of Nickel Cobalt cells, and essentially the same density at pack level since they don't require extensive cooling/safety systems due to inherent safety.

Solid state batteries may be like fusion at this point. The true economic victory for EVs is LFP/Sodium Ion (especially if the roadmap for 250wh/kg LFP and 200 wh/kg sodium ion bears fruit in a couple of years) which are the path to affordable city transportation with no cobalt, nickel, or even lithium. If fusion became "viable" in a sustained manner, it probably couldn't beat nuclear for LCOE cost. Likewise a mass produced solid state battery probably won't be more economical than the new LFP/Sodium Ion batteries for mass market cars. Will be very significant for trucks, short planes, etc though.

Of course why hasn't this trickled down yet? Apparently car manufacturers can't as effortlessly switch over as you suggest.

You seem very pro-Toyota. I would be very concerned about Toyota because they are 10 years behind and have dinosaurs for executive leadership. Kia/Hyundai have loads of fairly competitive EVs available, but still, crickets from Toyota and split mind syndrome over hydrogen. It's sad that the world leader in car manufacturing and the jewel of the Japanese economy is so asleep at the switch. There's still time, Toyota's engineers are no joke, and they can probably just buy / steal some Chinese EV company's tech and designs, or partner with Nissan.

Gas is inherently subsidized. First, nobody pays for the carbon, but I get the impression you aren't a global warming guy. Fine. The IMF says that fossil fuel subsidies were 7 trillion dollars last year. If one was honest, they'd realize that the US Navy and Marines exist as power projection to ensure oil resource access and shipping. Taxation in the US is for road construction, and has nothing to do with any environmental externalities and damage that fossil fuels are causing.