Even the most experienced fleet managers sometimes fall into costly traps and mistakes that chip away at profits, blow up repair budgets, and leave trucks stranded when they should be hauling freight.
If you’re trying to keep your buses and trucks out of the shop and on the road, steer clear of these seven fleet service mistakes. Trust us, your balance sheet will thank you.
Overlooking Preventive Maintenance
Skipping preventive maintenance might seem like a money-saving shortcut—until a breakdown leaves you with a $10,000 tow and repair bill. Regular inspections, oil changes, and filter replacements extend component life and prevent catastrophic failures. It’s not just about avoiding problems—it’s about catching them early.
That clunk in the transmission? Ignoring it now could cost you a whole gearbox later.
Neglecting Diesel Particulate Filter (DPF) Regeneration
Think your DPF can go forever without a regen? Think again.
DPF systems clog up with soot and need regular regeneration to burn off accumulated carbon. If your trucks are constantly in stop-and-go city traffic—like much of Chicago’s delivery fleet—they may not reach the operating temperatures needed for passive regen. Forced regen is an expensive and time-consuming process, leaving your truck in a repair bay and not on the road, making you money!
Miss enough regens, and you’re looking at a pricey DPF replacement and potential SCR system damage.
Skimping on Fluid Checks
Not maintaining your coolant system, transmission fluid, or engine oil can spell disaster. Transmission overheating, engine seizing, or premature differential failure all stem from neglected fluid care. Just one missed oil change could fry your turbocharger—and trust us when we tell you, that is not a cheap fix.
Mismanaging Tire Health
Heavy-duty fleets lose thousands every year from tire blowouts and irregular wear. Skipping tire pressure checks and alignment services can cost you more than a new set of tires. Underinflated tires increase fuel consumption, while poor alignment puts stress on suspension and steering components.
This can cause a blown tire, which is a one-way ticket to an accident on the road. Downtime, insurance headaches, and potentially life-threatening situations are all consequences of this.
Letting Driver Habits Slide
Driver behavior matters—a lot. Hard braking, poor shifting, and excessive idling don’t just waste fuel—they strain your brake system, wear out clutches, and build up carbon in your EGR system. If your drivers aren’t trained on how to operate a truck efficiently, you’re burning through DPFs, brakes, and even transmissions way faster than necessary.
Ignoring Suspension Wear
Bad suspension doesn’t just make for a rough ride—it affects vehicle stability, tire life, and cargo integrity. Ignoring worn leaf springs or air suspension components can cause major weight distribution issues. If left unchecked, this can lead to added wear on axle shafts, misaligned brakes, and even frame damage.
Cutting Corners on ECM Diagnostics
Computers run modern trucks. Avoiding ECM diagnostics during service visits is like ignoring your truck’s brain. Fault codes for sensors, fuel systems, or after-treatment systems might not trigger the check engine light—but they could signal a silent killer.
An unresolved DEF system issue or a bad sensor could be sapping power and fuel economy every mile. And with diesel prices the way they are, this is a mistake you can’t afford to make.
Final Thoughts
Fleets thrive on uptime. Every truck sidelined by a preventable issue is money out the door. Avoiding these seven costly service mistakes’ll protect your investments, keep your operations rolling, and improve your bottom line. Don’t wait until you’re stranded with a seized engine—build a smarter service strategy now with the help of professional fleet maintenance.