Semi-Truck Maintenance Checklist and Schedule

Last Updated November 18, 2024

As a carrier, one of the most important considerations required for running a successful trucking business is knowing how to keep your trucks in top condition—and the best way to do this is by following a semi-truck maintenance checklist.

A truck preventative maintenance program greatly reduces the risk of breakdowns and accidents on the road. It also ensures vehicles are prepared for DOT inspections, as they will be less likely to experience a serious repair issue that requires them to be put out of service.

With so many miles put in on the road and so many components to keep track of, understanding recommended truck service intervals and following a truck service checklist should be a top priority. Here’s what you should plan for.

What Is Preventative Maintenance in Trucking?

Preventative maintenance is one of the most important things you can do to care for your semi-truck. The idea behind preventative maintenance is that you follow a schedule that allows you to identify and address minor repair issues before they get out of hand.

A semi-truck maintenance program typically includes a semi-truck preventative maintenance checklist, which is a schedule for when to address key maintenance needs with a professional mechanic, such as replacing the power steering fluid or inspecting the brakes. This schedule is typically determined by manufacturer guidelines, as well as whether your vehicle use qualifies as “normal” duty or heavy/severe duty.

In addition to following this schedule, truck drivers should perform daily pre-trip and post-trip inspections to check for any defects or repair issues that may be present. When defects are found, they should be repaired as quickly as possible. All repairs and truck preventative maintenance (PM) service should be noted on a semi-truck maintenance log.

Why Is Semi-Truck Maintenance Important?

Semi-truck maintenance is crucial for trucking businesses for several reasons. First, keeping up with regular maintenance keeps your truck in good working order, reducing the likelihood of unexpected breakdowns. A breakdown caused by a mechanical failure could result in added expenses for towing and repairs, as well as lost income opportunities due to schedule delays.

Preventative maintenance also matters because, in some cases, mechanical failures could cause a serious accident. These accidents can result in significant damage to your truck and other vehicles and could even prove fatal. This is part of why the DOT conducts regular semi-truck inspections. A truck that fails the inspection will be placed out of service, further disrupting your operations. Effective maintenance keeps you compliant with regulations so your vehicles stay in service.

Finally, keeping up with preventative maintenance lowers costs for your trucking business by preventing more expensive repair issues and extending the lifespan of your vehicle. Following a manufacturer’s maintenance schedule is often required to maintain warranty coverage on repairs and replacements, regardless of whether you bought or leased your truck.

How Much Does Semi-Truck Maintenance Cost?

On average, semi-truck maintenance costs $15,000 per year per truck. The exact cost can vary based on factors like the age of your truck, its total mileage each year, and whether you operate it in “severe” conditions (such as driving in mountainous terrain).

Even with preventative maintenance, unexpected repairs and breakdowns are an inevitable part of any trucking business. Budgeting for these expenses can help ensure that such incidents don’t create a major financial setback.

Many owner-operators may also find they can lower their maintenance costs by leasing-on with companies that offer maintenance assistance programs or fleet discounts. Large truck repair chains usually offer service discounts nationwide.

How Often Is Semi-Truck Maintenance Required?

How often should you do truck maintenance? Quite often! Generally speaking, it is recommended that semi-trucks undergo basic service and inspection every 15,000-25,000 miles to check lights and brake functionality and refill any liquids. This also typically includes changing the oil, oil filters, fuel filters, and air filters.

Most semi-truck maintenance schedules follow a calendar and mileage-based approach. For example, the engine should be inspected yearly, regardless of mileage, to ensure it is in good working order. Batteries should be serviced (and replaced, if necessary) every six months. Other services are mileage-based, such as replacing the coolant filter and fan/accessory drive belt after 300,000 miles.

You should also account for seasonal truck maintenance. During summer, inspect the air conditioning for leaks or debris, and check the coolant system. During the winter, drivers should inspect their windshield for chips or cracks and confirm that the defroster is working properly. Qualified drivers should also verify ABS functionality and make sure the drum brakes do not freeze due to low temperatures.
Specific timelines for different services may vary between vehicle manufacturers, but owner-operators should always follow service guidelines listed in their owner’s manual.

Semi-Truck Maintenance Checklist

The following areas should receive consistent attention as part of your semi-truck PM service. Keep in mind that this list is not comprehensive and that other areas may also require consistent maintenance and inspections. Refer to your owner’s manual for guidelines specific to your semi-truck.

Tracking maintenance and repairs on a truck maintenance sheet will help you keep track of all service performed for these areas.

Cooling and Heating

• Check for leaks or debris in connections and hoses
• Repair or replace malfunctioning A/C and heating components
• Check A/C Freon level

Brakes

• Inspect brake pads to ensure proper thickness
• Look for leaks or other damage in the brake lines
• Inspect brake rotors, drum, and disc for damage
• Confirm parking brake operates properly
• Adjust rear brakes if needed

Lights

• Ensure headlights, warning lights, turn signals, brake lights, and emergency flashers are working properly
• Check for cracks or holes in lenses

Tires

• Check that tire air pressure matches inflation specifications
• Measure tread depth to ensure it is at least 4/32” on steer tires and 2/32” on other tires
• Check for dry rot, cuts, bulges, uneven wear, and other visible issues
• Check for cracks or other damage to rims and lug nuts
• Rotate tires regularly

Fluids

• Inspect for fluid reservoir leaks or tubing/connection leaks
• Monitor levels of coolant, power steering fluid, brake fluid, windshield wiper fluid, engine oil, transmission fluid, and DEF, and top off if necessary
• Visually inspect fluid for signs of debris and replace if needed
• Drain, flush, and replace fluid according to service timelines

Battery and Electrical Systems Inspection

• Test battery charge
• Inspect alternator and internal wiring
• Clean battery terminal corrosion
• Check for loose connections or damaged wires in the electrical system

General Cab and Trailer Inspection

• Check for fuel system leaks
• Check for leaks or soot in the cab/trailer exhaust system
• Ensure proper functioning of windshield wipers
• Confirm mud flaps are positioned properly
• Check for damage to the trailer landing gear, fifth wheel, pin, and assembly mounting
• Inspect cab, frame, and undercarriage for road salt during the winter and wash regularly to prevent corrosion
• Check steering play
• Inspect shocks, ball joints, springs, transmission mounts, bell housing bolts, and carrier bearings

Other General Maintenance Items

• Check air filters
• Inspect spark plugs
• Inspect the source of any dashboard warning lights and address repair needs in a timely manner
• Get professional maintenance service as recommended

Complete Semi-Truck Maintenance Schedule

Take a screenshot of the below semi-truck maintenance schedule or copy and save it in a document on your device.

Maintenance Item	Normal Duty Maintenance Schedule	Heavy Duty Maintenance Schedule
Oil change	15,000 miles	10,000 miles
Grease the fifth wheel and kingpin	Every 3 months or 30,000 miles	Every 3 months or 30,000 miles
Battery service	Every 6 months	Every 6 months
Replace air and cabin filters	Every 6 months	Every 6 months
Air filter fuel tank vent	Every 12 months	Every 6 months
Replace shocks	Every 12 months	Every 12 months
3-axle alignment	Every 12 months	Every 12 months
Replace air dryer filter	150,000 miles	100,000 miles
Clean/replace AHI	150,000 miles	100,000 miles
DEF system service	150,000 miles	150,000 miles
Replace power steering fluid	150,000 miles	150,000 miles
Valve adjustment	150,000 miles, then every 300,000 miles	150,000 miles, then every 200,000 miles
Replace differential oil	250,000 miles	150,000 miles
Replace fan/accessory drive belt	300,000 miles	150,000 miles
Replace coolant filter	300,000 miles	150,000 miles
Clean/bake DPF filter	400,000 miles	250,000 miles
Replace transmission fluid and filter	500,000 miles or after 60 months	500,000 miles or after 60 months
Replace/flush coolant	750,000 miles	750,000 miles
Replace tires	Every 3-6 years (when drive tire tread depth is less than 4/32” and other tires’ tread depth is less than 2/32”)	Every 3-6 years (when drive tire tread depth is less than 4/32” and other tires’ tread depth is less than 2/32”)

In-Summary: Semi-Truck Maintenance

Running a successful trucking company requires more than just finding profitable loads to haul or choosing the right trucking business financing solution. The little details matter just as much.

By using a semi-truck maintenance checklist to follow a consistent semi-truck maintenance program, you’ll keep your vehicles in good working order. This will prevent breakdowns and repair issues that could disrupt your work while also enabling your drivers to pass DOT inspections and helping you save money by avoiding more expensive repair costs.

Remember, PM service on trucks is ultimately a long-term investment for your business—one that will help you continue to operate efficiently and better serve your clients for many years to come.