Maintenance practices commonly overlooked in fleets

The most dangerous maintenance actions for a fleet are the ones that are not performed. According to Fleet Rabbit, a truck fleet management software, approximately 72% of truck breakdowns are caused by missed or delayed maintenance tasks. While most fleet managers understand the importance of general maintenance, such as oil changes and tire rotations, there are other maintenance tasks that are often overlooked.

According to Fleet Rabbit’s report, these overlooked tasks can cost a fleet an average of $12,000 to $18,000 per truck annually, with an average direct cost of $760 per unplanned maintenance incident.

Below are the processes most frequently overlooked, which should be a priority on every fleet and trucking maintenance checklist.

Maintenance practices commonly overlooked in fleets

Overlooked maintenance tasks are not unknown, they are simply postponed until it is too late. Fleet Rabbit classifies these tasks into four main categories:

1. Scheduled but skipped – Tasks listed on the maintenance calendar but postponed due to lack of parts, scheduling conflicts, or low revenue.
2. Assumed but not verified – Tasks carried out without proper documentation, often based on informal agreements.
3. Detected but unresolved – Issues identified during Driver Vehicle Inspection Reports (DVIR) or inspections that are documented but never turned into work orders.
4. Deprioritized – Issues labeled as “minor” that eventually grow into major problems.

These four categories result in:

• 35% of fleets missing quarterly maintenance intervals
• 25% of preventive maintenance tasks lacking verifiable records
• 60% of DVIR findings remaining unresolved for more than 7 days

8 maintenance practices commonly ignored

1. Brakes

Brake adjusters can fall out of calibration with use and are a leading cause of inspection failures. While some fleets check brakes annually, they should ideally be adjusted every 32,000–48,000 km. Timely, low-cost maintenance prevents expensive repairs.

2. Cooling System

Cooling system maintenance is often overlooked, leading to degraded coolant and loosened hoses over time. Ignoring preventive flushing and inspection can cause severe overheating, costly repairs, and several days of downtime.

3. Tire Pressure

Tire lifespan decreases as pressure drops over time, increasing fuel consumption and the risk of failure. Despite its importance, this check is often skipped, even though it is quick and easy.

4. Steering System

A $150 maintenance task can turn into a $6,000 failure. Steering components wear gradually, creating looseness that may go unnoticed. If not addressed early, it can lead to serious failures and costly repairs.

5. Lights and Reflectors

Fixing a faulty light is inexpensive, but ignoring it can lead to fines, delays, and penalties. Most of these issues can be avoided with a simple visual inspection.

6. Air System

Air leaks develop over time and can quickly put a vehicle out of compliance. They also increase brake wear if not detected early.

7. Oil (Analysis and Filtration)

While oil changes are performed, oil analysis is often skipped. This analysis helps detect internal issues early and prevent severe engine damage.

8. Fifth Wheel

Fifth wheel inspections are typically done during annual Department of Transportation inspections. Lack of lubrication can cause wear, mechanical failure, and even serious accidents.

What happens if these issues are ignored?

Ignoring ongoing truck maintenance can lead to more than just high costs and fines. According to Fleet Rabbit’s analysis, the most common consequences include:

• Higher repair costs: roadside assistance rates are four to six times higher than shop repairs
• Damaged CSA scores: out-of-service violations impact CSA scores for two years
• Safety and liability risks: documented lack of maintenance can lead to punitive liability cases

Do not forget to perform pre-trip inspections, schedule and attend maintenance services, and above all, take responsibility for your vehicles.