Common Preventive Maintenance Mistakes That Could Cost You Big

Want to know the best way to handle heavy-duty truck repairs? Stop them from happening in the first place with preventive maintenance. Catching potential problems before they develop into expensive and time-consuming problems is the key to smooth and effective operations. 

However, there are a few pitfalls that can actually cost you more down the road. But you don’t have to worry about that because we’re here to tell you what they are and how to avoid them! 

1. Neglecting Regular Inspections

Why Skipping Inspections Is Risky

It may seem like a tedious task, but avoiding regular inspections is the quickest way for your operations to grind to a halt. It may seem like you’re saving money and avoiding scheduled downtime, and you are…for a bit. But quickly, these issues will catch up with you, and you’ll wish you’d taken action sooner.

Sometimes, easily resolved problems like worn brake pads, low fluid levels, or cracked hoses are overlooked, which can lead to dangerous situations on the road. 

Actionable Advice

Set a strict inspection schedule for your truck, emphasizing preventive maintenance. It's even better if you invest in preventative maintenance software to help streamline the process.

2. Ignoring Fluid Changes

The Cost of Overdue Fluid Changes

Your truck relies on a series of different oils and fluids to ensure proper operation. As these fluids break down, they lose their ability to cool, lubricate, and protect engine and transmission components.

Skipping oil, transmission, power steering, or coolant system fluid changes can cause a range of problems. These include engine wear, overheating, and even catastrophic system failure. 

Actionable Advice

Follow a maintenance plan for fluid changes. For heavy-duty trucks, engine oil should typically be changed every 15,000 miles and transmission fluid every 50,000 miles. Always use the manufacturer-recommended fluids for the best performance.

3. Overlooking Air Filter and Fuel Filter Replacements

Why Filter Maintenance Matters

Air filters keep dust, dirt and contaminants out of your engine while the fuel filter allows for clean air to reach the injectors. Dirty or clogged filters increase emissions, reduce fuel efficiency, and lead to engine damage. Over time, clogged filters put extra strain on the engine, leading to reduced performance and fuel efficiency.

Actionable Advice

Inspect and replace filters as recommended by the manufacturer. A good rule of thumb is to replace air filters every 15,000 miles, and fuel filters every 25,000 miles. This helps the engine breathe clean air and get clean fuel, improving efficiency and extending engine life.

4. Failing to Maintain the Cooling System

The Risks of Cooling System Neglect

Heavy-duty trucks operate under extreme conditions, making a reliable cooling system essential. Neglecting the radiator, coolant, hoses, and belts can lead to overheating and catastrophic engine failure. Coolant that isn’t changed or topped off regularly loses its efficiency and can even corrode internal components over time.

Actionable Advice

Check coolant levels monthly, flush and refill the system every two years or as recommended by the manufacturer, and regularly inspect hoses and belts for cracks or wear, as these are the lifelines of your cooling system.

5. Ignoring Tire Maintenance

Why Tire Health Is Essential

Tires carry the full weight of a truck and its cargo, making tire maintenance critical. Underinflated or overinflated tires wear unevenly, reducing traction and increasing the risk of blowouts. Moreover, unbalanced or misaligned tires can strain the drivetrain and suspension.

Actionable Advice

Regularly check tire pressure and ensure it meets the manufacturer’s specifications. Rotate tires every 10,000 miles and perform alignment checks if you notice uneven wear. Inspect the tread depth and replace tires that have worn past the safe limit.

6. Not Testing the Battery and Electrical System

The Consequences of Electrical System Failures

A failing battery or electrical system can leave a truck stranded on the road, which is both costly and time-consuming. Diesel trucks rely on robust electrical systems to power critical functions, from starter motors to fuel injection systems.

Actionable Advice

Inspect the battery terminals for corrosion and make sure the battery holds a proper charge. Test the alternator and electrical wiring during routine maintenance. Replacing old batteries and inspecting the alternator every 100,000 miles can save you from unexpected failures.

7. Forgetting About Suspension and Shock Absorber Maintenance

Why Suspension Health Matters

Suspension issues can result in uneven tire wear, rough rides, and handling problems. A worn-out suspension system also affects other truck components due to increased vibrations and shocks. The shock absorbers are especially crucial because they control the truck’s rebound movement, minimizing wear on other parts.

Actionable Advice

Inspect suspension components regularly for wear and tear. Replace shock absorbers every 50,000 miles or sooner if you notice reduced handling or increased braking distance.

8. Postponing Brake System Servicing

The Hidden Costs of Brake Neglect

Heavy-duty truck brakes experience significant stress and wear, especially in stop-and-go or mountainous driving. Worn brake pads, leaking lines, or faulty slack adjusters can reduce braking efficiency, putting the driver and cargo at risk.

Actionable Advice

Inspect brake pads and replace them when they reach their wear limit. Check air lines, slack adjusters, and brake drums for proper function every 10,000 miles, especially before long hauls. For maximum safety, get a brake inspection at every oil change interval.

9. Overlooking DEF and Emission System Upkeep

The Price of Emissions System Neglect

Modern diesel trucks are equipped with Selective Catalytic Reduction (SCR) systems and Diesel Particulate Filters (DPF) to meet emission standards. Failing to refill DEF (Diesel Exhaust Fluid) or clean the DPF can lead to engine derating or fines for non-compliance with environmental regulations.

Actionable Advice

Refill DEF as needed and schedule DPF cleaning every 200,000 miles or when indicated by the system’s warning light. If the DPF becomes clogged, a forced regeneration may be required, so follow manufacturer recommendations to avoid this costly process.

Final Thoughts

Preventive maintenance isn’t just a task; it’s an investment in your truck’s performance and your business's profitability. By avoiding these common mistakes, you can extend the life of your truck, prevent costly repairs, and keep your operations running smoothly. 

Regular inspections, timely fluid changes, and attention to your truck’s tyres, brakes, and cooling system are essential. Take these steps to avoid unexpected breakdowns and keep your truck on the road where it belongs.

It’s getting cold outside, so make sure you’re up to date on what essential preventive maintenance you need to book this winter!